GB2595295A - Modular building having integrated guttering and assembly method - Google Patents

Abstract

A modular building 10 is provided having integrated guttering which comprises a plurality of vertical struts 38, each vertical strut 38 being at least in part hollow to form a down- pipe. A plurality of horizontal struts 3 has a gulley 34. Couplings 12 comprise an upper connectorportion 14 and a lower connector portion 16 respectively engagable with lower and upper ends 40, 42 of each said vertical strut 38, the upper and lower connector portions 14, 16 having a flow channel 22. The couplings 12 further comprise a lateral connector portion 18, an end of each horizontal strut 30 being receivably engagable with the lateral connector portion such that the gutter can discharge collected water into the coupling 12 and/or down-pipe. Also claimed is a method of constructing a vertical assembly with a strut, connectors and a connector rod. Also claimed is a horizontal assembly where the strut is inserted into the connector. Also claimed is a roofing assembly where a cap is vertically actuated to sealingaly engage with roof panels.

Description

Modular Building Having Integrated Guttering and Assembly Method The present invention relates to a modular building particularly, but not necessarily exclusively, for use in disaster relief settings. The invention further relates to a method of constructing a vertical assembly of a modular building and to a vertical assembly of a modular building. A method of constructing a horizontal assembly of a modular building is also provided, as is a method of assembling a modular building. A modular roofing assembly for a building is also provided, as is a method of assembly for a modular roofing assembly for a building.

Modular structures are known within the scope of accommodation, storage and office space, to provide cost-effective means of providing shelter. However, most modular structures are constructed from materials which are inappropriate in harsh environments, or in otherwise impoverished areas which would most benefit from a robust and cheap modular building.

In particular, water ingress is a problem for many temporary structures, which may not have the same degree of waterproofing or resistance to moisture which permanent structures may be afforded. As such, existing modular structures may not be suitable for use in disaster regions, particularly regions with flooding and/or monsoon conditions, since they will not be sufficiently resilient to the environmental conditions.

The present invention seeks to provide a modular building which is safe and affordable, 20 having mass-produced component parts of standard type, and which is suitable for use in areas otherwise inappropriate for existing temporary structures.

According to a first aspect of the invention, there is provided a modular building having integrated guttering, the modular building comprising: a plurality of vertical struts, each vertical strut being at least in part hollow to form a down-pipe; a plurality of horizontal struts, each horizontal strut having a gulley formed therein; and a plurality of couplings, each coupling comprising: an upper connector portion and a lower connector portion, the upper and lower connector portions being respectively engagable with lower and upper ends of each said vertical strut, the upper and lower connector portions having a flow channel therebetween; and a lateral connector portion, an end of each horizontal strut being receivably engagable with the lateral connector portion such that the gulley can discharge collected water into the coupling and/or down-pipe.

In many disaster relief contexts, particularly after floods or tsunamis, finding safe dry accommodation is critical to the relief effort. The present modular building can not only be constructed rapidly to suit the needs of the relief workers and survivors, but also has an inbuilt mechanism for draining water away from the building, so that rainwater does not cause damage to the structure. This renders the present invention a powerful tool for rapid response in disaster-struck regions.

Preferably, the vertical struts and/or horizontal struts may be shape-matingly engagable with the couplings.

A simple shape-mating or interference fit between the various struts and the couplings 10 provides a fast means of assembling the modular building in a toolless manner, which is particularly important where resources may otherwise be hard to obtain.

Optionally, the modular building may comprise a plurality of vertical assemblies, wherein each vertical assembly comprises a vertical strut and two couplings, a first said coupling being positioned at the lower end of the vertical strut, and the second said coupling being positioned at the upper end of the vertical strut, and further comprising a connector rod which connects to the first and second couplings through the down-pipe to secure the vertical assembly together.

The vertical assemblies of the present invention have a distinct advantage in the there is a connector rod which can provide stability and structural rigidity to the vertical 20 assembly while still retaining the ability for the vertical strut to drain water therethrough.

The vertical assembly may further comprise a foot portion engagable with the connector rod and/or first coupling.

A foot portion of the vertical assembly greatly improves the stability of the modular building, allowing it to be levelled more easily in uneven terrain.

Preferably, the plurality of vertical struts and/or the plurality of couplings may have any of a: rectangular cross-section; a square cross-section; a triangular cross-section; and a hexagonal cross-section.

Different cross-sections of the modular building can lead to different styles of building which can be constructed, improving the range of structures which can be built in 30 accordance with the system.

The modular building may further comprise at least one wall panel, the at least one wall panel being receivably engagable with a said horizontal strut.

Wall panels being readily engagable with the horizontal struts make for easy-toassemble structures.

Additionally, or alternatively, the modular building may, further comprise at least one floor or ceiling panel, each horizontal strut comprising a support member for supporting the at least one floor or ceiling panel.

A support member, such as a ledge, provides a simple mechanism for supporting a horizontal panel in place in the modular building, further improving the efficiency with 10 which the building can be toollessly assembled.

Optionally, there may be further provided a roofing assembly having a roofing vertical strut, a top coupling, and a plurality of rafter struts, the roofing vertical strut being engagable with an upper connector portion of a said coupling, and the plurality of rafter struts being engagable at an upper end with the top coupling and at a lower end with a said horizontal strut.

A roofing structure which utilises the same type of coupling arrangement as for the main body of the modular building further reduces the cost of mass-producing component parts for a full and complete building.

In one preferable embodiment, there may be provided a cap element engagable with the 20 top coupling, the cap element being engaged with a latching mechanism for vertical adjustment relative to the top coupling.

The capping of the roof assembly can be performed via a lifting latch mechanism inside the building, which means that the building can be finished off without needing to climb onto the roof, for example, with scaffolding.

Optionally, there may be at least one roofing panel, the roofing panel having a lip portion which is shaped to receivably engage with the gulley of a said horizontal strut.

Engagement of a roofing panel directly with the edge of the gulley encourages rainwater runoff directly into the gulley, so that water is channelled into the correct drainage system. This avoids unnecessary water ingress via the roof The modular building may further comprise a rafter cap engagable with the rafter strut, the rafter cap including a connection lug for engaging with the said horizontal strut.

A rafter cap serves to sealingly engage with roof panels inserted into the roofing assembly, whilst the pluggable lug forms a useful part of the toolless construction 5 technique.

Preferably, a blanking plate may be provided which is engagable with a lateral connector portion of the coupling.

A blanking plate is useful for sealing up flow openings in the couplings where one might otherwise not wish water to be ejected. The blanking plates also may have 10 supplementary benefits, such as providing a means of tethering the modular building in place.

In one preferable embodiment, there may be at least one buoyancy aid engagable with at least one of the vertical struts, horizontal struts, or coupling.

Buoyancy may be particularly useful in flooded areas, where dry land may be limited. 15 This will limit the risk to individuals in these areas, and may further reduce the risk of water-borne disease contagion.

According to a second aspect of the invention, there is provided a method of constructing a vertical assembly of a modular building, the method comprising the steps of: a] engaging a vertical strut with a first coupling by connecting a lower end of the vertical strut with an upper connector portion of the first coupling; b] engaging the vertical strut with a second coupling by connecting an upper end of the vertical strut with a lower connector portion of the second coupling; and c] connecting the first and second couplings using a connector rod to secure the vertical assembly together.

Optionally, the method may be performed toollessly.

According to a third aspect of the invention, there is provided a vertical assembly of a modular building comprising: a vertical strut; a first coupling; a second coupling; and a connector rod; the first coupling being engaged with the lower end of the vertical strut by connection with an upper connector portion of the first coupling, and the second coupling being engaged with the upper end of the vertical strut by connection with a lower connector portion of the second coupling; and the first and second couplings being connected using the connector rod to secure the vertical assembly together.

The method by which the vertical assemblies of the present invention are constructed creates strong and stable structures which will not bend. The upper and lower couplings 5 being linked created a powerful clamping force on the vertical strut, actively discouraging bending or flexing in use. This allows strong structures to be created.

According to a fourth aspect of the invention, there is provided a method of constructing a horizontal assembly of a modular building, the method comprising the steps of a] engaging a horizontal strut with a first coupling by inserting a first end of the horizontal strut into a lateral connector portion of the first coupling; and b] engaging the horizontal strut with a second coupling by inserting a second end of the horizontal strut into a lateral connector portion of the first coupling.

Preferably, the method may be performed toollessly.

The slotted engagement of the horizontal struts with the couplings provides an easy 15 mechanism of toolless engagement of the horizontal structure. Gravity natural holds the horizontal struts in position, negating the need to provide dedicated fasteners other than the coupling.

According to a fifth aspect of the invention, there is provided a method of constructing a modular building, the method comprising the steps of interconnecting a plurality of vertical assemblies formed in accordance with the method of the second aspect of the invention with a plurality of horizontal assemblies formed in accordance with the method of the fourth aspect of the invention to form a modular building.

The method preferably further comprises the step of constructing a roofing assembly on the modular building, by engaging a roofing vertical strut with an upper connector portion of a second coupling of one of the plurality of vertical assemblies, and engaging a plurality of rafter struts at an upper end with a top coupling of the roofing assembly and at a lower end of each of the plurality of rafter struts with one of the plurality of horizontal assemblies.

According to a sixth aspect of the invention, there is provided a modular roofing assembly 30 for a building, the modular roofing assembly comprising: a roofing vertical strut which is at least in part hollow; a plurality of rafter struts engagable with a top coupling associated with the vertical strut; a plurality of roof panels supportable by the rafter struts which form a roof covering; a top cap receivable over the top coupling; and a cap actuation means receivable within the roofing vertical strut to permit vertical actuation of the top cap to sealingly engage with the roof panels and/or rafter struts upon assembly of the modular roofing assembly from below the roof covering.

The roofing assembly of the present invention provides a simple means of creating a watertight roofing structure which naturally discharges into the gullies built into the modular building as previously discussed, whilst the engagement of the cap allows for simple construction of the roofing assembly. The top cap can be raised to insert the rafters and rafter caps, and lowered from the inside for ease to create a roofing seal.

According to a seventh aspect of the invention, there is provided a method of constructing a modular roofing assembly of a building, the method comprising the steps of: a] engaging a roofing vertical strut with the building, the roofing vertical strut being at least in part hollow and having a cap actuation means therein; b] engaging a top cap with the cap actuation means; c] connecting a plurality of rafter struts with a top coupling associated with the roofing vertical strut; d] engaging a plurality of roof panels with the plurality of rafter struts to form a roof covering; and e] activating the cap actuation means from below the roof covering to lower the top cap and sealingly engage with the roof panels and/or rafter struts.

During step c], each of the plurality of rafter struts may be engaged with the top coupling in a cantilever manner.

The method of installing the roofing assembly prevents the need for installers to climb onto the roof in a dangerous manner. Instead, the cantilevered rafter struts can be easily slotted into place from below, with the top cap ensuring water tightness once it is lowered 25 into place from the inside.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a side representation of one embodiment of a modular building in accordance with the first aspect of the invention; Figure 2 shows an isometric representation of a coupling of the modular building of Figure 1; Figure 3 shows a plan representation of the coupling of Figure 2; Figure 4 shows an isometric representation of a horizontal strut of the modular building of Figure 1; Figure 5 shows an isometric representation of a vertical strut of the modular building of Figure 1; Figure 6 shows an isometric representation of a framework module of the modular building of Figure 1 in which couplings, vertical struts and horizontal struts are connected together; Figure 7 shows an exploded isometric representation of the coupling of Figure 2 10 being engaged with a connector pin; Figure 8 shows an isometric representation of a tie rod assembly of the modular building of Figure 1, Figure 9 shows an isometric representation of a vertical assembly of the modular building of Figure 1; Figure 10 shows an isometric representation of the vertical assembly of Figure 9, including the locking element for holding the tie rod assembly securely; Figure 11 shows an isometric representation of the fully assembled vertical assembly of Figure 9, inclusive of a foot portion; Figure 12 shows an isometric representation of a framework module of the 20 modular building of claim 1, inclusive of a floor panel; a wall panel, and a ceiling panel; Figure 13 shows an isometric representation of the interconnection of a horizontal strut with a vertical assembly in the framework module of Figure 12; Figure 14 shows an isometric representation of a single-storey building module of the modular building of Figure 1; Figure 15 shows an isometric representation of a vertical roofing strut of a roofing assembly of the modular building of Figure 1; Figure 16 shows a plan representation of a rafter strut of the modular building of Figure 1; Figure 17 shows an isometric representation of the interconnection between the vertical roofing strut of Figure 15 and the rafter strut of Figure 16; Figure 18 shows an isometric representation of a roofing panel of the modular building of Figure 1; Figure 19 shows an isometric representation of the interconnection of the roofing panel of Figure 19 with the building module of Figure 15; Figure 20 shows an isometric representation of a rafter cap of the modular building of Figure 1; Figure 21 shows an isometric representation from below of the rafter cap of Figure 20; Figure 22 shows an isometric representation of the interconnection of the roofing strut and horizontal strut of the modular building of Figure 1; Figure 23 shows an isometric representation of the interconnection of the roofing cap and horizontal strut of the modular building of Figure 1; Figure 24 shows an isometric representation of a blanking panel of the modular building of Figure 1; Figure 25 shows an isometric representation of the roofing assembly of the 20 modular building of Figure 1, prior to lowering of the top cap; Figure 26 shows an isometric representation of the roofing assembly of Figure 26, following lowering of the top cap; Figure 27 shows an isometric representation of a buoyancy aid module used for a modular building as shown in Figure 1; Figure 28 shows an isometric representation of a fastener for the buoyancy aid module of Figure 27; Figure 29 shows an isometric representation of the modular building of Figure 1 in conjunction with a fully assembled buoyancy aid; Figure 30 shows an isometric representation of another embodiment of a modular building in accordance with the first aspect of the invention; and Figure 31 shows an isometric representation of another embodiment of a modular building in accordance with the first aspect of the invention.

Referring to Figure 1, there is shown a modular building, referenced globally at 10, which is particularly suited for use in challenging conditions as emergency shelter, such as war zones and disaster relief areas.

The modular building 10 is building from readily interengagable sub-units, such as panels, struts and couplings, to allow for a wide range of sizes and shapes of building to be constructed from a few base parts. The illustrated modular building 10 is based on a hexagonal base shape, but other geometries could be considered, such as rectangular, square, triangular, octagonal, circular, and so on.

Figures 2 and 3 show a coupling 12 used in the modular building. The coupling 12 comprises an upper connector portion 14, a lower connector portion 16, and at least one, and preferably a plurality of lateral connector portions 18. The lateral connector portions 18 extend radially outwardly of the upper connector portion 14, along the main axes of symmetry; in the depicted embodiment, there are six lateral connector portions 18.

The upper connector portion 14 is formed as a geometric recess, such as the hexagonal recess show, into which a complementary connector portion of another component is insertable. It is preferably geometrically complementary to the lower connector portion 16 to allow for stacking of couplings 12. By extension, the lower connector portion 16 is formed as a geometric plug or similarly insertable element, dimensioned to be receivable into, for example, an upper connector portion 14 of another coupling 12.

The upper and lower connector portions 14, 16 are in fluid connection with one another via at least one flow channel 20 therebetween. Three such flow channels 20 are provided in the indicated embodiment, separated by a web 22 which supports a central aperture 24.

The lateral connector portions 18 are formed in the wall of the coupling 12, facing outwardly, and may have a slotted receiver 26 for receiving a complementary engagement element on another component of the modular building 10. This slotted receiver 20 may have a T-shaped cross-section in plan, so as to prevent lateral ejection of the connected component.

One or more of the lateral connector portions 18 includes a flow opening 28 which permits fluid ingress from the lateral connector portion 18 into the upper connector portion 14. Only three of the lateral connector portions 18 includes a flow opening 28 in the depicted embodiment, and the remaining three lateral connector portions 18 are fluidly sealed from the upper connector portion 14. The flow openings 28 may be preformed in the coupling, or could be opened, cut or drilled in situ as required, for example, by the provision of knockout portions of the lateral connector portions 18 to allow for customisation of the modular building 10.

Figure 4 shows a horizontal strut 30 of the modular building 10. The horizontal strut 30 includes a plate connector 32 at each end which is shape-matingly engagable with the slotted receiver 26 of the lateral connector portion 18 of a coupling 12, though it will be appreciated that the shape mating is the important aspect of toolless engagement, rather than necessarily the specific shape of the plate connector 32.

The horizontal strut 30 includes a gulley 34 formed along its length which opens out to a 20 central area of the respective plate connectors 32 at each end thereof. When engaged with a lateral connector portion 18 of a coupling 12 having a flow opening 28, the gulley 34 is able to discharge into the upper connector portion 14 of said coupling 12.

Extending from each longitudinal side of the horizontal strut 30 is a support ledge 36 onto which panels of the modular building 10 are supportable. The edges of the support ledge 36 are cut or formed at at least 30° to the longitudinal axis of the horizontal strut 30 to permit tessellation of adjacent parts, though it will be apparent that this angular arrangement will depend on the geometry of sub-modules of the modular building 10, and in particular the coupling 12 geometry. The support ledge 36 is preferably positioned at the base of the horizontal strut 30, such that the wall of the gulley 34 forms a natural barrier to a panel supported on the support ledge 36 in use.

Figure 5 shows a vertical strut 38, which is here formed as a hollow hexagonal tube. A first, upper open end 40 of the vertical strut 38 is dimensioned to receive the lower connector portion 16 of the coupling 12, whilst the second, lower end 42 of the vertical strut 38 has a smaller diameter or width so as to be insertable into the upper connector portion 14 of the coupling 12. The lower end 42 of the vertical strut 38 includes one or more lateral openings 44 which, in use, align with the flow openings 28 of a coupling 12.

A framework module 46 of the modular building 10 is indicated in Figure 6. Vertical assemblies 48 can be constructed by connecting vertical struts 38 with a pair of couplings 12, one coupling at each end 40, 42 of the vertical strut 38, and the vertical assemblies 48 can be interconnected by horizontal struts 30 engaging with lateral connectors 18 of the couplings 12 of adjacent vertical assemblies 48. Such framework modules 46 form the building blocks of the modular building 10, allowing the modular building 10 to be upscaled as necessary.

The specific constructional steps for building the vertical assembly 48 is outlined in Figures 7 to 11.

To begin, a coupling 12 is selected, and a connector pin 50 inserted into the central aperture 24 from below. The connector pin 50 includes a lip or flange 52 at one end of an elongate body 54 thereof, which prevents the connector pin 50 from being completely drawn through the central aperture 24. The elongate body 54 has an internal thread for engaging with a connector rod 56, as can be seen in Figure 8.

The connector rod 56 is dimensioned so as to extend through the length of a vertical strut 38, without blocking up the internal void therein. For ease of assembly, the connector rod 56 may be provided as a separate component, but it will be apparent to the skilled person that the connector rod 56 could readily be integrally formed with the connector pin 50, with the coupling 12 being threaded onto the connector rod 56 during assembly of the vertical assembly 48, thereby forming a tie-rod assembly 58.

Once the connector rod 56 is in position, the vertical strut 38 can be installed, as shown in Figure 9, by engaging the lower end 42 with the upper connector portion 14 of the coupling 12. As can be seen, the flow openings 28 of the coupling 12 have been aligned to the lateral openings 44 of the vertical strut 38 so that fluid passage into the upper connector portion 14 of the coupling 12 remains possible.

A second coupling 12 is then inserted into the upper end 40 of the vertical strut 38, so that the connector rod 56 extends through the central aperture 24. This can be seen in more detail in Figure 10. A locking nut 60 or similar fastener can then be engaged with the top of the connector rod, effectively securing the upper and lower couplings 12 to one another and clamping the vertical strut 38 in position to form the vertical assembly 48.

A foot portion 62 can be attached to the vertical assembly 48, as shown in Figure 11, preferably via the connector pin 50 with the foot portion 62 being screw-threadingly engaged with the internal thread. The foot portion 62 may have a ground contact area which is larger than a cross-sectional area of the vertical strut 38, so as to provide improved support for the vertical assembly 48.

The framework module 46 of Figure 6 is shown with more component parts introduced in Figure 12. There is a floor panel 64, a wall panel 66, and a ceiling panel 68.

The floor and ceiling panels 64, 68 may be identical to one another, or may have different characteristics based on their intended use. The floor and ceiling panels 64, 68 are triangular here, but will be dimensioned according to the geometry of the modular building 10. The floor and ceiling panels 64, 68 rest in place on the support ledges 36 of the horizontal struts 30, whilst the wall panel 66 abuttably engagable with a wall of the gulley 34 of a lower horizontal strut 30 and a complementary locator on the underside of an upper horizontal strut 30. This keeps the gulley 34 free from blockage by the wall panel 66, as well as keeping the wall panel 66 dry.

The specific engagement between a horizontal strut 30 and a coupling 12 is shown in Figure 13. The plate connector 32 of the horizontal strut 30 is insertable into the slotted receiver 26 of the coupling 12, with a neck 70 of the gulley 34 aligning with the flow opening 28 of the upper connector portion 14 of the coupling 12. Water which collects in a gulley 34 of an upper horizontal strut 30 can disgorge into the upper connector portion 14 as a gutter, discharging into an associate vertical strut 38 which in turn acts as a downpipe. Water can therefore discharge from a lower coupling 12.

A full gutter arrangement can be seen in the single-storey building module 72 of Figure 14. The upper horizontal struts 30 can collect rainwater in their gullies 34, which can then flow down the vertical assemblies 48 acting as downpipes. The wall panels, which are here provided as plain wall panels 66a and a window panel 66b, are dimensioned so that the lower edge is spaced apart from the gulley 34 of the lower horizontal strut 30. This keeps the gulley 34 free for water flow. Water in the lower couplings 12 can either discharge through the flow channels 20, or via outward-facing flow openings 28.

The ceiling panels 68 are not designed to be waterproof alone. Instead, a roofing assembly 74 is used to construct a complete and watertight roof covering. This is 5 discussed in Figures 15 to 26.

Figure 15 shows a roofing vertical strut 76 which is at least in part hollow, and within which a cap actuation means is provided. Here, the cap actuation means is a latching mechanism 78 for raising and lowering brackets 80 connected to a top cap 82 of the roofing assembly 74.

The roofing vertical strut 76 has a lower end 84 which is dimensioned to be received in an upper connector portion 14 of a coupling 12, such as the centre-most coupling 12 of the building module 72 of Figure 14, whilst a top coupling 86 is provided at an upper end 88 of the roofing vertical strut 76, and which may be integrally formed therewith. The top cap 82 is designed to cover the top coupling completely in plan.

A rafter strut 90 is shown in Figure 16, which has a connector plate 92 at an upper end 94 which is connectable to the top coupling 86, as is shown in Figure 17. The lower end 96 of the rafter strut 90 is free of connectors, making the rafter strut 90 a cantilevered component. The rafter strut 90 has a rafter ledge 98 on either longitudinal side, which is designed to support roof panels 100.

An indicative said roof panel 100 is shown in Figure 18. As with the floor and ceiling panels 64, 68, the roof panel 100 has a triangular geometry, thereby fitting with the construction of the hexagonal modular building 10.

At an in-use lower edge 102 of the roof panel 100, there is a hook or lip 104 which is configured to engage with an upper edge of a gulley 34 of a horizontal strut 30. This connection can be seen in Figure 19. This connection method ensures that water flows from the roof panel 100 into the gulley 34, rather than into an attic space above the ceiling panels 68 of the modular building 10. Figure 19 also shows the bottom of the rafter strut 90, which has a locator portion 106 receivably engagable in the gulley 34 of an underlying horizontal strut 30. This is not an issue for water ingress; there is no flow opening connecting to the horizontal strut 30, and therefore the locator portion 106 does not block the flow channel formed therein. Instead the locator portion 106 serves to align the rafter strut 90 to the horizontal strut 30.

To prevent water ingress into the rafter strut 90 or underlying horizontal strut 30, a rafter cap 108 is provided, which is shown in Figures 20 and 21. This is a unitary component designed to completely cover the length of the rafter strut 90 and then plug the end of the gulley 34 of the horizontal strut 30 via the depending lug 110 at the lower end 112 thereof. The lug 110 is dimensioned to wedgingly engage with the neck 70 of the gulley 34, and the two-step engagement process can be seen in more detail in Figures 22 and 23.

Whilst it may be possible to form a rafter strut with an integrally formed cap, the use of the specific rafter cap 108 allows for the longitudinal edges to overlie and seal against the roof panels 100 underneath the rafter cap 108 and connected to the rafter strut 90 via the rafter ledges 98. As can be specifically seen from Figure 23, the lower end 112 of the rafter cap 108 is positioned to discharge into the gullies 34 of adjacent horizontal struts 30, as well as the upper coupling 12. An indented portion 114 of the rafter cap 108 is provided at the lower end 112, to permit a further vertical strut 30 to be installed as required, should a multi-storey construction be desirable.

A blanking plate 116 is also shown in Figure 23, and in more detail in Figure 24, which allows for flow openings 28 of the coupling 12 to be blocked off. The blanking plate 116 has a perimetric lip 118 which corresponds with that of the plate connector 32 of horizontal struts 30, so that the same shape-mating engagement can be used. A tether point 120 can also be provided on the blanking plate 116, as a convenient means of providing guy lines to the modular building 10, which may be important in stormy or windy environments, as well as particularly flooded areas.

At the upper end 122 of the rafter cap 108, as shown in Figure 25, the rafter cap 108 lies under the area covered by the top cap 82 Once all rafter caps 108 are in place, as is the case in Figure 26, the top cap 82 can be lowered into position by use of the latching mechanism 78. Significantly, this can all be performed from the inside of the modular building 10, and there is therefore no need for extensive scaffolding to complete the overall roof covering 124 of the roofing assembly 74.

In some disaster zones, particularly those where flooding is prevalent, it may be useful to provide a buoyancy aid 126 for the modular building 10, as can be seen from Figures 27 to 29. The modular building 10 can be provided with a full perimeter buoyancy aid 126 formed of a plurality of buoyancy aid modules 128 which are interengagable using one or more fasteners 130. Interconnection of the buoyancy aid modules 128 can form a complete float for the modular building 10, with the buoyancy aid 126 completely extending under the modular building 10 and having an upstanding perimeter barrier 132 to limit water ingress towards the modular building 10, and which can also form a walkway which may interconnect modular buildings and/or other pathways.

The modular building 10 shown up to this point has been a single storey unit. However, the strength of the present modular building system is that different bespoke 10 constructions can be made to suit the needs of the user.

Figure 30 shows a second embodiment of a modular building 1010, still based around the hexagonal geometry previously discussed, but now incorporating a plurality of individual building modules 1072 connected together. The walls panels between adjacent modules are omitted if required, to create a large open space, and multi-storey buildings can be considered.

In a multi-storey configuration, the advantage of the way the rafter caps engage with the horizontal struts ensures that the rainwater is diverted into common gullies without contacting the outside of the wall panels of the modular building 1010.

Figure 31 shows a third embodiment of modular building 2010. The underlying construction of the building is unchanged, but is now based on a square geometry system, instead of hexagonal. Different building shaped can therefore be considered. It may be possible to mix and match components from different geometric systems, for example, by having a rectangular annex on the standard hexagonal base building.

The pitch of the roofing assembly 2074 for the third modular building 2010 is slightly 25 different, and will require pitched caps 2082 and vertical panels 2134, instead of just sloping panels as required in the hexagonal configuration.

For any of the modular buildings described, there are various construction materials which could be used. For example, the components could be built from recycled plastics, timber, glass-reinforced plastic, ballistic panels, and so on.

One of the main advantages of the present system is that the assembly of the modular building is toolless, and therefore is highly suited for use in disaster zones where resources may be very limited.

Additional optional extra features could also be considered, for example, a power source, such as a ground heat exchanger, solar panels, or a solid fuel burner. Refrigeration units or air conditioning units could also be provided. Where the buoyancy aids are included, an outboard motor could also be utilised, to limit the risk of the modular building being washed away by flood water.

Indeed, other types of wall, ceiling or floor panel could be considered in order to adapt 10 the purpose of the modular building. For example, tinted glass panels could be used to create a greenhouse environment, or insulated panels could be used for a refrigeration building It is therefore possible to provide a modular building which can be constructed in a toolless manner, and which is highly suited for use in disaster relief efforts. The modular building has integrated guttering formed as part of its base components, which limits risk in stormy conditions without exposing the inhabitants to the wet. Furthermore, the roofing assembly of the present modular building has also been designed in such a way as to simplify assembly, reducing the need for climbing or working at elevation which will be safer and easier to construct.

The words 'comprises/comprising' and the words 'having/including' when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various 30 other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.

Claims (23)

1. Claims 1. A modular building having integrated guttering, the modular building comprising: a plurality of vertical struts, each vertical strut being at least in part hollow to form a down-pipe; a plurality of horizontal struts, each horizontal strut having a gulley formed therein; and a plurality of couplings, each coupling comprising: an upper connector portion and a lower connector portion, the upper and lower connector portions being respectively engagable with lower and upper ends of each said vertical strut, the upper and lower connector portions having a flow channel therebetween; and a lateral connector portion, an end of each horizontal strut being receivably engagable with the lateral connector portion such that the gulley can discharge collected water into the coupling and/or down-pipe.
2. 2. A modular building as claimed in claim 1, wherein the vertical struts and/or horizontal struts are shape-mafingly engagable with the couplings.
3. 3. A modular building as claimed in claim 1 or claim 2, wherein the modular building comprises a plurality of vertical assemblies, wherein each vertical assembly comprises a vertical strut and two couplings, a first said coupling being positioned at the lower end of the vertical strut, and the second said coupling being positioned at the upper end of the vertical strut, and further comprising a connector rod which connects to the first and second couplings through the down-pipe to secure the vertical assembly together.
4. 4. A modular building as claimed in claim 3, wherein the vertical assembly further comprises a foot portion engagable with the connector rod and/or first coupling.
5. 5. A modular building as claimed in any one of the preceding claims, wherein the plurality of vertical struts and/or the plurality of couplings have any of a: rectangular cross-section; a square cross-section; a triangular cross-section; and a hexagonal cross-section.
6. 6. A modular building as claimed in any one of the preceding claims, further comprising at least one wall panel, the at least one wall panel being receivably engagable with the said horizontal strut.
7. 7. A modular building as claimed in any one of the preceding claims, further comprising at least one floor or ceiling panel, each horizontal strut comprising a support member for supporting the at least one floor or ceiling panel.
8. 8. A modular building as claimed in any one of the preceding claims, further comprising a roofing assembly having a roofing vertical strut, a top coupling, and a plurality of rafter struts, the roofing vertical strut being engagable with an upper connector portion of a said coupling, and the plurality of rafter struts being engagable at an upper end with the top coupling and at a lower end with a said horizontal strut.
9. 9. A modular building as claimed in claim 8, further comprising a cap element engagable with the top coupling, the cap element being engaged with a latching mechanism for vertical adjustment relative to the top coupling.
10. 10. A modular building as claimed in claim 8 or claim 9, further comprising at least one roofing panel, the roofing panel having a lip portion which is shaped to receivably engage with the gulley of a said horizontal strut.
11. 11. A modular building as claimed in any one of claims 8 to 10, further comprising a rafter cap engagable with the rafter strut, the rafter cap including a connection lug for engaging with the said horizontal strut.
12. 12. A modular building as claimed in any one of the preceding claims, further comprising a blanking plate engagable with a lateral connector portion of the coupling.
13. 13. A modular building as claimed in any one of the preceding claims, further comprising at least one buoyancy aid engagable with at least one of the vertical struts, horizontal struts, or coupling.
14. 14. A method of constructing a vertical assembly of a modular building, the method comprising the steps of: a] engaging a vertical strut with a first coupling by connecting a lower end of the vertical strut with an upper connector portion of the first coupling; b] engaging the vertical strut with a second coupling by connecting an upper end of the vertical strut with a lower connector portion of the second coupling; and c] connecting the first and second couplings using a connector rod to secure the vertical assembly together.
15. 15. A method as claimed in claim 14, wherein the method is performed toollessly. 5
16. 16. A vertical assembly of a modular building, the vertical assembly comprising: a vertical strut; a first coupling; a second coupling and a connector rod; the first coupling being engaged with the lower end of the vertical strut by connection with an upper connector portion of the first coupling, and the second coupling being engaged with the upper end of the vertical strut by connection with a lower connector portion of the second coupling; and the first and second couplings being connected using the connector rod to secure the vertical assembly together.
17. 17. A method of constructing a horizontal assembly of a modular building, the method comprising the steps of: a] engaging a horizontal strut with a first coupling by inserting a first end of the horizontal strut into a lateral connector portion of the first coupling; and b] engaging the horizontal strut with a second coupling by inserting a second end of the horizontal strut into a lateral connector portion of the first coupling.
18. 18. A method as claimed in claim 17, wherein the method is performed toollessly.
19. 19. A method of constructing a modular building, the method comprising the steps of interconnecting a plurality of vertical assemblies formed in accordance with the method 30 of claim 14 or claim 15 with a plurality of horizontal assemblies formed in accordance with the method of claim 17 or claim 18 to form a modular building.
20. 20. A method as claimed in claim 19, further comprising the step of constructing a roofing assembly on the modular building, by engaging a roofing vertical strut with an 35 upper connector portion of a second coupling of one of the plurality of vertical assemblies, and engaging a plurality of rafter struts at an upper end with a top coupling of the roofing assembly and at a lower end of each of the plurality of rafter struts with one of the plurality of horizontal assemblies.
21. 21. A modular roofing assembly for a building, the modular roofing assembly comprising: a roofing vertical strut which is at least in part hollow; a plurality of rafter struts engagable with a top coupling associated with the vertical strut; a plurality of roof panels supportable by the rafter struts which form a roof covering; a top cap receivable over the top coupling; and a cap actuation means receivable within the roofing vertical strut to permit vertical actuation of the top cap to sealingly engage with the roof panels and/or rafter struts upon assembly of the modular roofing assembly from below the roof covering.
22. 22. A method of constructing a modular roofing assembly of a building, the method comprising the steps of: a] engaging a roofing vertical strut with the building, the roofing vertical strut being at least in part hollow and having a cap actuation means therein; b] engaging a top cap with the cap actuation means; c] connecting a plurality of rafter struts with a top coupling associated with the roofing vertical strut; d] engaging a plurality of roof panels with the plurality of rafter struts to form a roof covering; and e] activating the cap actuation means from below the roof covering to lower the top cap and sealingly engage with the roof panels and/or rafter struts.
23. 23. A method as claimed in claim 22, wherein during step c], each of the plurality of rafter struts is engaged with the top coupling in a cantilever manner.