GB2610429A

GB2610429A - Metal-construction-beam connector system, construction module using said system, and a method of construction

Info

Publication number: GB2610429A
Application number: GB2112664.4A
Authority: GB
Inventors: John Whitworth Samuel
Original assignee: Stelling Modular Ltd
Current assignee: Stelling Modular Ltd
Priority date: 2021-09-06
Filing date: 2021-09-06
Publication date: 2023-03-08
Also published as: GB202112664D0

Abstract

Herein disclosed is a metal construction beam connector system for weldlessly and/or threadlessly interconnecting construction beams comprising a pin-support element 28 (fig. 6a) for location on a first beam portion 14a attached to a connector pin 30. The connector pin 30 has a first fastener opening 38 (fig.6a). A socket element 32 is provided for location on a second beam portion 14b, having a pin receiving opening 36 the socket element having a second fastener opening 40 (fig.4a). A fastener pin 34 is receivable in the second and first fastener openings to secure the connector pin in the socket element. Also disclosed is a construction beam apparatus, building framework module, and modular building including the aforementioned connector system. Further disclosed is a method of constructing and disassembling a modular building and a separate connector system wherein a fastener pin is inserted perpendicularly to the axis along which a first connector portion engages a second.

Description

Metal-Construction-Beam Connector System, Construction Module Using Said System, And A Method Of Construction The present invention relates to a metal-construction-beam connector system, more specifically but not necessarily exclusively for weldlessly interconnecting metal construction beams of buildings on site. The invention also relates to construction beam apparatus using such a connector system; and to a building-framework module utilising at least a part of the said connector system. Furthermore, the invention relates to a method of improving the speed of on-site building-framework module assembly and disassembly.

Construction of low-rise and high-rise buildings via the combination of multiple modules is well known. This process allows for high-rise buildings to be assembled much more quickly, as the metal frames of the modules can be prefabricated before being shipped to site. However, since the modules are provided as separate units stacked on top of one another, they must be provided so as to be sturdy and stable. For high-rise buildings, resistance to lifting effects caused by wind load is critical, as high winds can create large forces to topple buildings due to the moments involved.

The act of welding said modules together on the construction site itself can prove to be hazardous as well as time consuming, particularly when modules are being connected at a significant height and a focus on welding quality is needed.

The most common means of interconnecting building modules is to provide an elongate threaded element which spans two modules, and which is receivable inside the vertical support beams of the two modules. The modules can then be secured in position by engaging the counterpart nuts using a long tool which can reach inside the void of the vertical support beams. This means that access to the internal regions of the vertical support beams is essential.

Utilising screw-threaded bolts overcomes the issues with welding but can take enormous amounts of time to fasten. And, once engaged, adjustment is time consuming, and relocation of the bolt holes becomes troublesome.

The assembly of multiple building blocks using either bolts or welding takes a significant amount of time. This can lead to delays to the estimated construction completion date due to potential lack of assembly materials required to secure the building framework. This delay can incur significant costs for the use of other machinery used in the construction process.

Once the decision has been made to remove the building from the area, the usual method includes an aspect of demolition and/or destruction of the building as the framework is welded together irreversibly. This method can be once again time consuming and dangerous. There is always the risk that someone will be injured by falling debris from the destruction of a building. There is the additional factor of acquiring planning permission and other documents in order to demolish a building, not to mention the demolition process itself and the removal of the resulting debris. Overall, the demolition process is time consuming.

Levelling a building during construction is difficult. If it appears that the level is not ideal, then it is potentially necessary to cut down the welded frames or start the construction again if appropriate. This will add to the construction time and a number of attempts of creating a level surface may be required.

The present invention seeks to provide a solution to the above-mentioned problems.

According to a first aspect of the invention, there is provided a metal-construction-beam connector system for weldlessly and/or threadlessly interconnecting metal construction beams of buildings on site, the metal-construction-beam connector system comprising: a pin-support element for location on a first beam portion of a said metal construction beam; a connector pin which is attached to the pin-support element and which projects therefrom; the connector pin having a first fastener opening, axes of the connector pin and the first fastener opening extending at a first angle to each other; a socket element having a pin-receiver opening which is complementarily shaped to receive the said connector pin, the socket element being located or locatable on a second beam portion of a second metal construction beam; each said socket element having a second fastener opening, axes of the pin-receiver opening and the second fastener opening extending at a second angle to each other; and a fastener pin which is receivable in the second fastener opening of the socket element and the first fastener opening of the connector pin, so that the connector pin is securable in the socket element to weldlessly and/or threadlessly interengage the said first and second beams portions.

Such a connector system avoids the necessity of requiring welding and/or screw-threaded bolting of construction beams on-site. Welding requires the use of potentially hazardous welding apparatus, which becomes increasingly unsafe once in an elevated position above the ground. In the present invention, modular units can be readily interengaged using the simple location method of the connector pins with the socket elements, with the fastener pin allowing for simple but secure connection of said modules together. Rapid construction of buildings can thus be achieved. The engagement of the fastener pins in a horizontal plane limits the lifting effect on stacked modules which might otherwise be expected with such a simple connection means.

Preferably, the connector pin may be a rigid elongate member. This enables simplified location of the socket member when assembling frame modules on-site.

The connector pin may include a leading end portion and a trailing end portion at or adjacent to the pin-support element, the leading end portion being or including a tapering surface for promoting insertion into said pin-receiver opening of the socket element. The tapered end of the leading portion encourages a faster and easier insertion into the socket element, and thus overall reducing the on-site construction time.

The said first fastener opening may preferably be a through-bore which extends through a lateral or substantially lateral extent of the pin body. If the first fastener opening extends all the way through the pin body, the corresponding fastener pin can be dimensioned to span the pin body as well. This significantly reduces the risk of slippage or breaking of the fastener pin in situ, as load will be relatively distributed evenly along its length.

Preferably, the second fastener opening may extend either side of the through-bore. This allows the fastener pin to extend through both of the first and second fastener openings in order to allow for a secure fastening between the connector pin of the first beam portion and the socket element of the second beam portion.

Optionally, the fastener pin may be a rigid elongate retaining member receivable in the second fastener opening to form an interference fit. The, preferably sliding, push-fit insertion of the fastener pin on-site allows for particularly rapid interengagement and secure fastening. The interference fit is defined as a fastening between two mating parts, namely a male and a female part, for a tight fit aided by friction.

Preferably, the said fastener pin may be devoid of a screw-thread. The lack or omission of a screw thread again facilitates rapid slidable receipt of the fastener pin, for example, utilising a hammer or similar impaction device, in the respective openings. It also allows straightforward removal, for example, by the use of a dedicated magnetic removal tool.

Preferably, the pin-support element may be provided as a rigid cap for capping or substantially capping an end of said first beam portion. The rigid cap, in this case, may be fixed to the part of the beam, strut or panel at a first off-site location, thereby increasing the speed of construction once transported to the second on-site location. By having a cap attached to the beam, this helps spread the load applied when stacking modules during assembly, improving stability.

Optionally, the pin-support element may be a planar plate. Such a plate, cover or support may be a thick metal sheet or block, for example, which can be attached safely via welding at the aforementioned off-site location, again reducing assembly time on-site.

Beneficially, the pin-support element may be integrally formed with the connector pin. The connector pin can be welded to the pin support element at an off-site location to allow for efficient assembly of the modules on-site.

Preferably, the socket element may include a socket body for capping or substantially capping an end of said second beam portion. The socket body, in this case, may be fixed to the part of the second beam portion at a first off-site location, thereby increasing the speed of construction once transported to the second on-site location. By having a cap attached to the beam, this provides a body for the pin-receiver opening to be locatable on.

The pin-receiver opening of the socket element is preferably a through-hole through the socket element. This through-hole is advantageous as it may allow for an interference fit between the connector pin and the socket element and thus secures the interconnection of the metal construction beams before the fastener pin is inserted.

Optionally, the connector pin may include a pin body having a uniform or substantially uniform lateral cross-section along at least a majority of its longitudinal extent. Having a uniform cross section will improve the ease with which the connector pin is received into the corresponding socket element, with reduced likelihood of snagging or catching thereon.

In the aforementioned case, the pin body may be cylindrical or substantially cylindrical. The cylindrical shape creates a smoother and easier connection process on-site compared to a shape including three or more vertices and simplifies manufacture.

According to a second aspect of the invention, there is provided a metal construction beam comprising: a metal elongate beam body; and a metal-construction-beam connector system in accordance with the first aspect of the invention; wherein the pin support element and connector pin of the metal-construction-beam connector system are positioned on a first end of the metal elongate beam body, and the socket element of the metal-construction-beam connector system being positioned on a second end of the metal elongate beam body.

Preferably the pin support element and connector pin may be positioned on a first end and a second end of a construction beam respectively. Therefore, the first and second beam portions form a collective connector system which can couple to corresponding parts of connector systems on other metal construction beams.

According to a third aspect of the invention, there is provided a metal-construction-beam apparatus comprising: a first metal construction beam; a second metal construction beam; and a metal-construction-beam connector system in accordance with the first aspect of the invention; wherein the pin support element and connector pin of the metal-construction-beam connector system are positioned on a first beam portion of the first metal construction beam, and the socket element of the metal-construction-beam connector system being positioned on a second beam portion of the second metal construction beam.

Advantageously, the pin support element and connector pin may be positioned on opposing construction beams on a first end and a second end respectively. This is advantageous because the connector pin can complementarily align with the socket element of a further metalconstruction-beam and provide a secure fit before the fastener pin is inserted to form the building-framework module.

According to a fourth aspect of the invention, there is provided a building-framework module for forming part of a weldlessly-interconnected building framework, the building framework module comprising: a framework comprising a plurality of metal construction beams; and a plurality of metal-construction-beam connector systems in accordance with aspect the first aspect of the invention associated with the building framework, to permit interengagement of at least one further said building-framework module therewith at least in part via said plurality of metal-construction-beam connector systems.

The advantage of creating building-framework modules which can be assembled off-site and easily assembled in situ is clear; the speed with which buildings can be constructed, in particular high-rise buildings, is massively improved. Furthermore, the simplicity with which the fastener pins can be introduced as a means of connection allows for the building-framework modules to be largely shipped in a complete or near-complete condition, that is, with some or all of the facades and/or internal fixings already in place.

The building-framework module formed through the metal-construction-beam apparatus may preferably be as a cuboidal or a cuboid frame. Additionally, or alternatively, the building-framework module may also include or be a panel frame. Being able to form or produce the modules in various geometric shapes, such as in polygonal form or as flatter panels, enables simpler off-site construction, storage and transport. The greater the degree of off-site assembly, however, the simpler on-site construction becomes.

Such a building-framework module may be stackably engageable with at least one further said building-framework module. The building-framework module may also be provided as a three-dimensional framework or a two-dimensional panel, for example, typically utilises beams requiring interconnection. This enables far more rapid on-site weldless and/or threadless construction of the required building or structure due to the cuboidal shape. Simple modular building assembly can thus be achieved.

Advantageously, the second fastener openings of the plurality of metal-construction-beam connector systems may be preferably aligned to permit insertion of the fastener pins from an external side. The second fastener opening being accessible from the external side of the building-framework module rather than from within the building-framework module is advantageous, since it means that the building-framework module can be supplied in a part or fully fixed state, and then the connections to other modules can be made without causing damage to said fixings. A key benefit of the invention is that it is not necessary to expose the module to the elements to make the connection with the fastener pin. This can be done completely from the outside without opening the building-framework module for access.

Preferably, the connector pins of the plurality of metal-construction-beam connector systems may be aligned to face in parallel with one another and extend from the same face of the building-framework module. This is advantageous because this allows for more efficient interengagement of the building-framework modules as the connector pins and the socket elements are interengageable at the same orientation.

According to a fifth aspect of the invention, there is provided a building construction system comprising a plurality of building-framework modules in accordance with the fourth aspect of the invention. The presence of a plurality of building-framework modules advantageously results in the construction of a multi-storey building. I nterconnectable modules allows for a high degree of flexibility in the construction of the building by the designers or architects.

Advantageously, the construction beam apparatus may further comprise at least one tie element for connecting horizontally adjacent building-framework modules together. The tie element, such as a tie plate, enables two or more neighbouring stacked modules to be horizontally interengaged. This can result in a building with varying numbers of building-framework modules forming the base of the building, and thus creating the potential to form different size buildings.

Advantageously, the construction beam apparatus preferably comprises at least one shim element engageable with the connector pin and/or pin support element of the or each metalconstruction-beam connector system to permit levelling of stacked building-framework modules. Spacing apart said beams allows for the optimal or improved alignment and levelling of the first and second fastener openings on-site, and levelling of the building-framework modules. Thus, a good fit for the fastener pin to secure the construction is also achieved. Advantageously, the use of shim plates overcomes any issues with tolerance in the manufacture of the building-framework modules allowing for rapid construction.

In this case, said shim element may be one of a plurality of selectable shim elements having different thickness. Not only does this allow for a range of tolerances to be accommodated in the manufacture of the beams, but the variation of thickness also provides options for the insertion or accommodation of additional optional building features, such as corridors and balconies in the form of secondary building-framework modules, before the opposing construction beam is located or engaged therewith.

The, or at least one, said shim element preferably may have a thickness corresponding to a frame-linking arm element. This corresponding thickness between the frame-linking arm element and the shim allows for levelling between the beams or associated modules formed therefrom.

The building construction system further comprising a fastener-pin alignment jig engageable with the connector pin and/or pin support element of the or each metal-construction-beam connector system which is dimensioned to determine a number and/or size of the at least one shim element required for levelling. In this case, the utilisation of a jig improves the speed of on-site building-framework module assembly as the correct level of the building storey is attained.

Said jig is more specifically but not necessarily exclusively provided as a practice block. The use of the jig is advantageous as this practice block or similar device allows for an accurate thickness of the shim plate to be gauged.

The building construction system may further include a fastener-pin extractor device for extracting a fastener pin once received in the second fastener opening to allow for disassembly of the building construction system. Enabling rapid dismantling of the construction beam apparatus on-site is advantageous in certain circumstances, for example, when needing to demolish a structure, modify, extend and/or realign due to subsidence and the like. The ability to recycle modular parts can therefore reduce the lifetime carbon footprint of the building to be assembled, since many parts can be reused.

In this case, the fastener-pin extractor device may include a magnetic element. This magnetic element creates a simple avenue for removing the fastener pin during, but not limited to, disassembly or realignment of the opposing construction beams.

Preferably, the building construction system may further comprise at least one secondary building-framework module engageable at least one of the plurality of metal-construction-beam connector systems. The secondary building-framework module may bridge neighbouring building-framework modules, at least part of a perimeter portion of the secondary building-framework module interengaging said metal-construction-beam connector system. The secondary building-framework module advantageously allows for interconnection and bridging of adjacent building-framework modules which are stacked in spaced-apart relationship. This means that corridors, balconies, doors, windows, and other such structural elements can be incorporated without necessarily including all of the individual components of a metal-construction-beam connector system.

In the aforementioned case, the secondary building-framework module may include one or more cantilevered tangs for location on said connector pin of at least one of the plurality of metalconstruction-beam connector systems. The cantilevered arm elements, known as connector tangs, conveniently support a body of the secondary building-framework module on the connector pins, whilst also tying together the neighbouring stacks of modules.

According to a sixth aspect of the invention, there is provided a modular building formed using a building construction system in accordance with the fifth aspect of the invention. Such a modular building can be constructed very rapidly, and without causing damage to internal or external fixings during the connection process of the modules.

According to a seventh aspect of the invention, there is provided a method of providing an enhanced modular building construction process, the method comprising the steps of a] at a location which is remote from a building-site location, pre-forming a plurality of building-framework modules, preferably in accordance with the fourth aspect of the invention; b] transporting the plurality of building-framework modules to the said building-site location; and c] interengaging the plurality of building-framework modules using the plurality of metal construction-beam connector systems via a plurality of horizontally insertable threadless fastener pins at interfaces of the building-framework modules.

Advantageously, the method reduces the construction time of a building on-site as individual modules are assembled off-site and then subsequently transported on-site for the construction of the resultant building.

Optionally, second fastener openings of the plurality of building-framework modules may be aligned to permit insertion of the fastener pins from an external side. The accessibility of the second fastener openings is advantageous for the installation of the fastener pin because this allows for more efficient installation of the fastener pin to secure the connector pin and the socket element.

According to an eighth aspect of the invention, there is provided a method of improving the speed of disassembly of a modular building, the method comprising the steps of a] using a fastener-pin extractor device, extracting the fastener pins of the metal construction-beam connector systems of a modular building in accordance with the sixth aspect of the invention; and b] separating the plurality of building-framework modules from one another.

The use of an extractor device improves the speed of dismantling the building-framework modules. The extraction of the fastener pin using the fastener-pin extractor device provides an efficient means of disassembling the building structure when needing to demolish, modify, extend and/or realign a structure due to subsidence and the like.

According to a ninth aspect of the invention, there is provided a connector system for interconnecting construction beams of buildings on-site, the connector system comprising: first and second mutually interengageable connector portions respectively mounted on adjacent construction beams to be interconnected, the first and second connector portions respectively having first and second fastener receivers, the first connector portion being receivably engageable along a first axis into the second connector portion to align the first and second fastener receivers; and a fastener pin insertable into the first and second fastener receivers to couple the first and second connector portions together along a second axis which is perpendicular to the first axis.

Such a connector system may be advantageous as the first and second connector portions are interengageable along a first axis. This first axis aligns the first and second fastener receivers to receive the fastener pin when the modules are being secured. This insertion of the fastener pin into the first and second receivers is at a second axis perpendicular to the first axis. The advantage of having the axes perpendicular to each other provides the secure engagement of adjacent construction beams.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is an isometric view of a plurality of stacked frame modules interengaged via an embodiment of a building framework comprising a metal-construction-beam connector system, in accordance with the invention; Figure 2 is an isometric view of the building framework of Figure 1, in cross-section along the plane indicated by line A-A; Figure 3 is a side view of the building framework of Figure 2; Figure 4 is an enlarged isometric sectional view of the metal-construction-beam connector system of the building framework indicated in region W of Figure 3; Figure 5a is an enlarged perspective view of the socket element of a metal-construction-beam connector system in accordance with the first aspect of the invention; Figure 5b is a plan view of the socket element of Figure 5a showing the second fastener opening in dashed lines; Figure 6a is an enlarged perspective view of a connector unit of a metal-construction-beam connector system in accordance with the first aspect of the invention, with the first fastener opening in one orientation; Figure 6b is an enlarged view of the connector pin and pin-support element in with the first fastener opening in a second orientation; Figure 7 is an enlarged isometric view of the metal-construction-beam connector system of the building framework indicated in region X of Figure 4; Figure 8 is an enlarged side view of the metal-construction-beam connector system of the building framework indicated in region Y of Figure 4; Figure 9 is an isometric sectional view of the building framework of Figure 1, in cross-section along the plane indicated by line B-B; and Figure 10 is an enlarged sectional view of the metal-construction-beam connector system of the building framework shown in region Z of Figure 9.

Referring firstly to Figure 1 there is shown an indicative weldlessly-interconnected building construction system, referenced globally at 10, from which a modular building can be assembled. The building construction system 10 comprises a plurality of building-framework modules 12 which are modularly interconnectable. Each building-framework module 12 in the illustrated embodiment is provided as a cubic structure having four vertical construction beams 14 and eight horizontal construction beams 16 which interconnect the four vertical construction beams 14. A complete building is not shown, since the building-framework modules 12 can be assembled in any appropriate manner based on the form of the building to be constructed.

The vertical construction beams 14 are in the illustrated embodiment hollow and the horizontal construction beams 16 are shown as C shaped beams. Said vertical construction beams 14 may be hollow rectangular tubes for example. The horizontal construction beams 16 connect the vertical construction beams 14 and thus form the building-framework module 12.

The specific form of the construction beam is context dependent, and the skilled person will be aware of the sort of beam that can be used in various construction beams. Other shapes of construction beam are available such as H beams and I beams and no limitation to beam shape or construction is intended within the scope of this invention.

The building-framework modules 12 have been assembled in two stacks of two-by-two, to form building structures 18, and the two stacks have been interconnected by a secondary building-framework module 20 to form the building construction system 10. However, it is possible that the building structure 18 comprises of a larger number of building-framework modules 12 to form a larger base for the building. For example, the two stacks can be at least two-by-two so can also be three-by-two.

The secondary building-framework module 20 is shown as a bridge element forming a corridor, but a wide variety of different modules can be utilised to interconnect with the primary building-framework modules 12 to create a building however the designer sees fit. Some of these options include, and are not limited to, the addition of a roof or balcony to the framework, as well as the potential use for window ledges Interconnection of the building-framework modules 12 is achieved by engagement of the vertical construction beams 14 of the building-framework modules 12 with one another. It will be appreciated that the present invention could be used to interconnect individual beams as a construction beam apparatus in a linear, co-axial fashion if necessary, but the present description will be directed towards the interconnection of building-framework modules 12, which will likely be more useful on-site.

The interconnection of adjacent vertical construction beams 14 can be seen in more detail in Figures 2 and 3, which shows more detail regarding the metal-construction-beam connector system 22 of the present invention.

When describing the interconnection of adjacent vertical construction beams 14, there will be an upper construction beam and a lower construction beam. The lower construction beam is hereafter described as a first construction beam 14a, with the upper construction beam being described as a second construction beam 14b. This generalisation acknowledges that there is no explicit requirement for verticality when interconnecting adjacent construction beams 14a, 14b and/or building-framework modules 12. For example, building-framework modules 12 could be interconnected in a horizontal direction rather than being stacked without altering the form of the present invention.

At the first end of the first construction beam 14a there is a first beam portion 24, at the second end of the first construction beam 14a there is a second beam portion 26. The first beam portion 24 is the upper portion of any in-use vertical construction beam 14 with the second beam portion 26 being the lower portion of said vertical construction beam 14. This of course will be dependent on construction beam orientation and thus first and second beam portions 24, 26 are used for convenience.

As illustrated, in more detail in Figure 4, showing the area indicated in region W of Figure 3, the metal-construction-beam connector system 22 comprises a pin-support element 28 at the first end, and therefore first beam portion 24, of said vertical construction beams 14, a connector pin 30 on the pin-support element 28 and a socket element 32 at the second end, and therefore second beam portion 26, of said vertical construction beams 14. This generalisation acknowledges that there is no explicit requirement for the connector pins 30 and socket element 32 to be positioned on the relevant ends of the vertical construction beams 14 as long as the position of the said connector pins 30 and socket elements 32 align. For example, the connector pins 30 and socket elements 32 could be positioned at any location on the building-framework module 12.

It is preferred that, for any given building-framework module 12, that all of the connector pins are positioned on the same side, that is, the upper side thereof. Similarly, all of the socket elements 32 are preferably positioned at the same end of each building-framework module 12 locatable on the corners. The metal-construction-beam connector system 22 also includes a fastener pin 34. The fastener pin 34 is used to engage the connector pin 30 with the socket element 32. By also including a fastener pin 34, the connector pin 30, when received in or by the socket element 32, can be securely engaged.

The pin-support element 28 is preferably a planar or a substantially planar plate. However, a domed plate and corresponding pin-receiver opening may be feasible as may other non-planar arrangements. The pin-support element 28 is provided to support the connector pin 30 and as a result the pin-support element 28 is integrally formed with the connector pin 30. The pin-support element 28 also caps or substantially caps a first beam portion 24 of the first construction beam 14a. The planar plate has a first end surface and a second end surface opposing the first end surface. The planar plate also has first, second, third and fourth side surfaces extending between the first and second end surfaces.

The pin-support element 28 is preferably cuboidal in shape. However, the planar plate may be cruciform or stellate in shape with a varying number of arm extensions originating from the relative location of the through-hole. These varying shapes will result a plurality of side surfaces extending between the first and second end surfaces. Additionally, the planar plate can also be cylindrical including one continuous side surface extending between the first and second end surfaces.

The planar plate is preferably a metal planar plate; however, the planar plate is not only limited to purely metal fabrication. Examples of suitable materials include aluminium, steel, plastic, 15 and wood.

The connector pin 30 is connected to the pin-support element 28, for example via welding. The connector pin 30 has a pin base at one extremity of the connector pin 30 which leads through the through-hole of the pin-support element 28. The connector pin 30 has a pin body; said pin body has a uniform or substantially uniform lateral cross-section along at least a majority of its longitudinal extent.

The connector pin 30 is preferably a rigid elongate member and is preferably a cylinder or substantially cylindrical. In a preferred arrangement, said connector pin 30 may have a tapered end to promote insertion of the connector pin 30 into a pin receiver or pin-receiver opening 36 of the second construction beam 14b, formed as part of the socket element 32. The connector pin 30 can also be cylindrical, frusto-conical, or polygonal in shape to complementarily fit into the pin-receiver opening 36. The connector pin 30 includes a leading end portion and a trailing end portion at or adjacent to the pin-support element 28, the leading end portion being or including a tapering surface. Nothing precludes the inclusion of different forms of the connection interface. Interfacing doesn't need to include just one connector pin 30, it can also include the use of a plurality of connector pins 30 as long as the number of connector pins 30 and the pin-receiver openings 36 are complementary and align with one another. However, the use of the single connector pin 30 is optimal for the case of structural security.

The connector pin 30 preferably has a through-bore which extends through a lateral or substantially lateral extent of the pin body. The through-bore preferably extends through the entire extent of the pin body. The axes of the connector pin 30 and the through-bore extend at first angles to each other. In the illustrated embodiment, the connector pin 30 and through-bore are perpendicular to one another, and therefore said first angle is 90 degrees. However, further examples include the scenario where the first angle is an acute angle or obtuse angle. Said through-bore is preferably circular in shape but can also have a polygonal shape with at least one or more vertices in accordance with the shape of the fastener pin 34. Said through-bore is hereafter referred to as a first fastener opening 38. However, there can be a plurality of first fastener openings 38 extending through the connector pin 30.

The connector pin 30 projects from the pin-support element 28. Preferably the connector pin 30 projects at right angles to the pin-support element 28. However, it may be possible for the connector pin 30 to project at an acute angle from the pin-support element 28 but the present description will be directed towards the perpendicular arrangement, which will likely be more useful, stable and ensure faster assembly of the building-framework modules 12 on-site.

The connector pin 30 is preferably metal, but it can also be made of a different solid material. As with the pin-support element 28, examples of suitable materials include aluminium, steel, plastic, and wood.

The socket element 32 is welded to the second beam portion 26 and has a pin-receiver opening 36 which is complementarily shaped to receive the connector pin 30. Each said socket element 32 has a second fastener opening 40, which aligns with the first fastener opening 38 of the connector pin 30. However, there can be a plurality of second fastener openings 40 extending through the socket element 32 in order to align with a plurality of first fastener openings 38.

The socket element 32 has a socket body which caps the end of the second beam portion 26 and also receives the connector pin 30. The metal block has a vertical aperture through the extent of the metal block or a partial indent into the metal block to align with and receive the connector pin 30 as two building-framework modules 12 are attached. The aperture is generally referred to as a pin-receiver opening 36. There can also be the presence of a plurality of pin-receiver openings 36 to align with the potential plurality of connector pins 30.

The socket body is preferably a metal block. The metal block is not limited to being fabricated from metal and can also be made out of other solid materials including but not limited to aluminium, steel, plastic, and wood.

The pin-receiver opening 36 of said socket body is preferably a circular through-hole, but can also be polygonal in shape, in order to form an interference fit with the shape and position of the connector pin 30. The metal block is a cuboid of significant depth in order to contain both the vertical pin-receiver opening 36 and the horizontal second fastener opening 40. The second fastener opening 40 is accessible from the outside of the second beam portion 26 of the vertical construction beam 14 and thus it is accessible from the side of the socket element 32.

The second fastener opening 40 is preferably circular in shape but can also have a polygonal shape with at least one or more vertices in accordance with the shape of the fastener pin 34.

Said second fastener opening 40 extends either side of the through-bore of the connector pin and thus forming an alignment of the first and second fastener opening 38, 40.

The fastener pin 34 is part of the metal construction beam connector system 22. Said fastener pin 34 is receivable in the first and second fastener openings 38, 40 so that the connector pin 30 is weldlessly secured in the socket element 32. As a result, this interengages the said first and second beam portions 24, 26 of the first and second construction beams 14a, 14b and thus interengage the building-framework module 12.

The fastener pin 34 is, for example, preferably a rigid elongate retaining member receivable into a fastener receiver formed by the alignment of the first and second fastener openings 38, 40, from the outside of the building-framework module 12, and thus devoid of a screw thread mechanism. Said fastener pin 34 is receivable as an interference fit into the first fastener opening 38 of the connector pin 30 and second fastener opening 40 of the socket element 32 when interengaged and therefore secures the interengagement of the building-framework modules 12.

The fastener pin 34 can be extracted from the first and second fastener openings 38, 40 using a fastener pin extraction device. The fastener pin 34 is preferably magnetic but can also be non-magnetic and instead consist of a ridged elongate retaining member with an extraction handle attached to the end of the exposed end of the fastener pin 34.

Figures 5a, 5b, 6a and 6b show the aforementioned socket element 32 and a connector unit 41, comprising the connector pin 30 and the pin-support element 28 in further detail.

Figure 5a and 5b specifically show the second fastener opening 40 extending through the socket element 32.

Figure 6a shows a first orientation option for the first fastener opening 38 through the connector pin 30. Figure 6b shows an alternative orientation option for the first fastener opening 38' depending on the position of the outer surface of the metal-construction-beam connector system 22 in order to insert the fastener pin 34 into the first and second fastener openings 38, 40.

Figure 4 shows two alternative connection instances of the metal-construction-beam connector system 22, which are respectively shown in more detail in Figures 7 and 8 from regions X and Y in Figure 4.

Figure 7 shows a direct connection between first and second construction beams 14a, 14b, with first and second shim plates 42a, 42b spacing apart said first and second construction beams 14a, 14b. The first and second shim plates have different thicknesses to correctly level the stacked building-framework modules 12. Each shim plate 42a, 42b is preferably a metal plate used to level the interconnection between the building-framework modules 12 but other appropriate materials include aluminium, steel, wood, and plastic. Each shim plate 42 has a first locator hole 44 through which the connector pin 30 can fit, and thus the shim plate 42 rests directly or indirectly on top of the pin-support element 28. The first locator hole 44 is preferably circular in shape but can also have a polygonal shape with at least one or more vertices in accordance with the shape of the connector pin 30. The shim plate 42 can have a plurality of first locator holes 44 depending on the number of connector pins 30.

Different shim plates 42 have different thicknesses in order to space apart the opposing first and second construction beams 14a, 14b depending on the level needed to align the first and second fastener openings 38, 40.

Figure 8, on the other hand, shows a connection between first and second construction beams 14a, 14b which also secures the secondary building-framework module 20 in position. A connector tang 46 of the secondary building-framework module 20 is also connected over the connection pin 30 of the first construction beam 14a before the socket element 32 of the second construction beam 14b is positioned. Said connector tangs 46 of the secondary building-framework module 20 are preferably provided as one or more cantilevered arm elements preferably located at the peripheries of the secondary building-framework module 20 for location on said connector pin 30.

The connector tangs 46 are preferably L shaped metal attachments welded to the peripheries of the secondary building-framework module 20. Said connector tangs 46 have preferably circular second locator holes 48 to be receivable over the connector pins 30 of the building-framework modules 12 and the connector tangs 46 preferably rest on top of the shim plate 42, described in more detail hereafter. The second locator hole 48 is preferably circular but can also have a polygonal shape with at least one or more vertices in accordance with the shape of the connector pin 30. There can be a plurality of second locator holes 48 depending on the number of connector pins 30.

The secondary building-framework modules 20 potentially block access to the second fastener opening 40. To accommodate the problem, a third fastener opening is provided.

Said connector tangs 46 are able to receive the fastener pins 34 via a third fastener opening 50. Said third fastener opening 50 is located at the vertical face of the secondary building-framework module 20, possibly through a vertical face of the connector tang 46. The third fastener opening 50 is preferably a circular aperture but can also have a polygonal shape with at least one or more vertices in accordance with the shape of the fastener pin 34. The aperture is available to fit the fastener pin 34 once a plurality of building-framework modules 12 have been interconnected in the vertical direction.

Third and fourth shim plates 42c, 42d are illustrated here, having different thicknesses to the first and second shim plates 42a, 42b. The third and fourth shim plates 42c, 42d provide the correct level for receiving the connector tang 46 thereon. This specific thickness is utilised when the secondary building-framework module 20 is received over a connector pin 30.

Figures 9 and 10 show the connection between two neighbouring building-framework modules 12 in the horizontal direction. Specifically, the metal construction beam connector system 22 is indicated in region Z of Figure 9, and shown in detail in Figure 10. The use of a first and second tie plates 52a, 52b is illustrated in detail. Said tie plate 52a, 52b is a further metal plate that has at least two connecting apertures 54 to link at least two building-framework modules 12. At least two connecting apertures 54 are receivable over at least two connector pins 30 and preferably rest on top the pin-support elements 28. Said tie plates 52a, 52b can also have three of more connecting apertures 54 if there are more than two building-framework modules 12 being connected horizontally. However, there can be a plurality of connecting apertures 54 also dependant on the number of connector pins 30 on each pin-support element 28.

In accordance with the shape of the connector pin 30, the connecting apertures 54 are preferably circular in shape but can also have a polygonal shape with at least one or more vertices. The tie plates 52a, 52b are preferably metal fie plates but other appropriate materials include aluminium, steel, wood and plastic.

Prior to the assembly of a building, the metal construction beams are interconnected at an off-site location to form the cuboidal building-framework modules. The preformed building-framework modules have the connection apparatus welded to the top and bottom, and thus the first and second beam portions, of the module. The connection apparatus includes the connector pin and the socket elements. The modules are then subsequently transported to the on-site location.

The building is assembled weldlessly on site. Building-framework modules are placed and interconnected using the tie plates in the horizontal direction. Said fie plates are positioned over the relevant connector pins of neighbouring modules. By doing this, a footprint of the building can be created to a desired size. Specific shim plates are positioned over the remaining connector pins in anticipation of the secondary building-framework module and to level the placement of the next storey of building-framework modules.

In order to gauge the required thickness of the shim plate, a fastener-pin alignment jig can be utilised. Said fastener-pin alignment jig is a practice panel identical to the shape and structure of the base of a module and can be easily removed from the connector pins of the module.

The fastener-pin alignment jig thus has practice socket elements at the corners which are slidably receivable over the connector pins of the first module. The placement of the fastener-pin alignment jig allows for the required thickness of the shim plate to be concluded in order for the alignment of the first, second and third fastener openings.

The shim plates are then received over the connector pins. The secondary building-framework module is placed between neighbouring building-framework modules at a distance via the connector tangs to form a corridor. Said connector tangs are placed over the connector pins of neighbouring connector pins on one plurality of modules and distant connector pins at the second plurality of modules. Said first and second plurality of modules are separate stacks of building-framework modules that can be connected via the secondary building-framework module. This results in the connection of two pluralities of modules via bridging.

The next storey of modules is interconnected on top of the first storey of modules. The socket elements at the corners of the base of the next storey of modules are slidably received by the connector pins of the first storey of modules. Due to the levelling provided by the shim plates, the first and second fastener openings, and optionally the third fastener openings, are aligned.

It is at this step that the advantageous effects of the present invention become apparent. Entire floors of the building can be effectively lifted into place and will automatically be correctly aligned if the levelling process has been performed satisfactorily.

The building-framework assembly demonstrates the ease of construction. The building-framework modules are simply placed on top of one another and subsequently secured using the fastener pins. This process is extremely fast to assemble, and with the addition of the insertion of the fastener pin, prevents the building-framework modules from being lifted off the modules below unless disassembly is required. Additionally, a number of building-framework modules can be installed and secured at once as they are straightforward to interconnect as well as the lack of welding, once again reducing the construction time on-site.

In order to secure the connection between the connector pins and socket elements of upper storey modules, a fastener pin is received, preferably from the outside of the module, by the first and second fastener openings, and where applicable, third fastener openings. This results in an interference fit and secures the interconnected modules in the vertical direction. The insertion of the fastener pins may be identified by the use of a wax seal over the second fastener opening once the fastener pin is secure. In doing so, this allows for quick identification of which fastener pins have been correctly inserted and locked in place. This process of fastener pin insertion is extremely fast to assemble, much more so that the screw-threaded arrangements currently available in the art.

The process is repeated until the required module height is achieved. This metal-constructionbeam connector system forms the frame of the building. The formation of a frame allows for the efficient attachment of the building's façade once the frame has been completed.

The simplicity of the locking system using the fastener pins means that there is need to access the internals of the building framework once the fastener pins have been introduced. As such, it becomes possible for the building framework modules to be provided with much of the fixings installed in advance of installation. This could include, but is not limited to, the building façade, floors, walls, studwork, doors, and windows, which would otherwise take significant time to install on site. Building construction is greatly accelerated.

If a balcony is required, a module component similar to the secondary building-framework module may be placed over the connector pins of one plurality of modules so as to not connect two distant pluralities of modules. Therefore, the opposite end that is not placed over the connector pins is suspended horizontally outwards from the modules. The secondary building-framework module is cantilevered via the interconnection of the modules.

A subsequent use of the metal-construction-beam connector system includes the method of disassembly. Rather than the utilisation of dangerous demolishment, the metal-construction-beam connector system can be disassembled by gaining access to the fastener pins through the façade of the building.

Once the fastener pins are exposed, they are extracted using a relevant method depending on the material of the fastener pin. If the fastener pin is magnetic then it is extracted using a magnet and if the fastener pin has a handle attached to the end then it is extracted by being pulled out.

After the removal of the fastener pin, the relevant level of modules can be removed safely by lifting them off the connector pins of the modules below. Therefore, the modules have the potential to be retained in shape and used again in another construction, preserving resources.

The metal-construction-beam apparatus includes the combination of the first and second construction beams individually without the necessary construction of the modules first. The said beams are interconnected using the metal-construction-beam connector system wherein the pin support element and connector pin of the metal-construction-beam connector system are positioned on a first beam portion of the first metal construction beam. The socket element of the metal-construction-beam connector system is positioned on a second beam portion of the second metal construction beam. The socket element and the connector pin are interengaged via the connector pin being received into the pin-receiver opening. Once this is complete, the fastener pin is received into the first and second fastener openings to secure the interconnection. This interconnection of the first and second construction beams only will be useful if there is a requirement to assemble a plurality of beams at the offsite location. It is therefore possible to provide a construction system that prevents or reduces the requirement for welding on a construction site and results in efficient assembly and thus reduces the overall construction time. Due to the exclusion of welding on-site, work-related injuries will be avoided.

There is also the possibility of having a connector system for interconnecting construction beams of buildings on-site. The connector system comprises first and second mutually interengageable connector portions respectively mounted on adjacent construction beams to be interconnected. The first and second connector portions respectively have first and second fastener receivers, and the first connector portion is receivably engageable along a first axis into the second connector portion to align the first and second fastener receivers. A fastener pin is insertable into the first and second fastener receivers to couple the first and second connector portions together along a second axis which is perpendicular to the first axis.

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 other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.

Claims

Claims 1 A metal-construction-beam connector system for weldlessly and/or threadlessly interconnecting metal construction beams of buildings on site, the metal-construction-beam connector system comprising: a pin-support element for location on a first beam portion of a said metal construction beam; a connector pin which is attached to the pin-support element and which projects therefrom; the connector pin having a first fastener opening, axes of the connector pin and the first fastener opening extending at a first angle to each other; a socket element having a pin-receiver opening which is complementarily shaped to receive the said connector pin, the socket element being located or locatable on a second beam portion of a second metal construction beam; each said socket element having a second fastener opening, axes of the pin-receiver opening and the second fastener opening extending at a second angle to each other; and a fastener pin which is receivable in the second fastener opening of the socket element and the first fastener opening of the connector pin, so that the connector pin is securable in the socket element to weldlessly and/or threadlessly interengage the said first and second beams portions.
2. A metal-construction-beam connector system as claimed in claim 1, wherein the connector pin is formed as a rigid elongate member.
3. A metal-construction-beam connector system as claimed in claim 1 or claim 2, wherein the connector pin includes a leading end portion and a trailing end portion at or adjacent to the pin-support element, the leading end portion being or including a tapering surface for promoting insertion into said pin-receiver opening of the socket element.
4. A metal-construction-beam connector system as claimed in any one of the preceding claims, wherein the said first fastener opening is a through-bore which extends through a lateral extent of a pin body of the connector pin.
5. A metal-construction-beam connector system as claimed in claim 4, wherein the second fastener opening extends either side of the through-bore.
6. A metal-construction-beam connector system as claimed in any one of the preceding claims, wherein the said fastener pin is a rigid elongate retaining member receivable in the second fastener opening to form an interference fit.
7. A metal-construction-beam connector system as claimed in any one of the preceding claims, wherein the said fastener pin is devoid of a screw-thread.
8. A metal construction beam comprising: a metal elongate beam body, and a metal-construction-beam connector system as claimed in any one of the preceding claims; wherein the pin support element and connector pin of the metal-construction-beam connector system are positioned on a first end of the metal elongate beam body, and the socket element of the metal-construction-beam connector system being positioned on a second end of the metal elongate beam body.
9. A metal-construction-beam apparatus comprising: a first metal construction beam; a second metal construction beam, and a metal-construction-beam connector system as claimed in any one of claims 1 to 7; wherein the pin support element and connector pin of the metal-construction-beam connector system are positioned on a first beam portion of the first metal construction beam, and the socket element of the metal-construction-beam connector system being positioned on a second beam portion of the second metal construction beam.
10.A building-framework module for forming part of a weldlessly-interconnected building framework, the building framework module comprising: a framework comprising a plurality of metal construction beams; and a plurality of metal-construction-beam connector systems as claimed in any one of claims 1 to 7 associated with the building framework, to permit interengagement of at least one further said building-framework module therewith at least in part via said plurality of metal-construction-beam connector systems.
11. A building-framework module as claimed in claim 10, wherein the building-framework module is stackably engageable with at least one further said building-framework module.
12.A building-framework module as claimed in claim 10 or claim 11, wherein the second fastener openings of the plurality of metal-construction-beam connector systems are aligned to permit insertion of the fastener pins from an external side thereof.
13.A building-framework module as claimed in any one of claims 10 to 12, wherein the connector pins of the plurality of metal-construction-beam connector systems are aligned to face in parallel with one another and extend from the same face of the building-framework module.
14.A building construction system suitable for assembling a modular building, the building construction system comprising a plurality of building-framework modules as claimed in any one of claims 10 to 13.
15. A building construction system as claimed in claim 14, further comprising at least one tie element for connecting horizontally adjacent building-framework modules together.
16. A building construction system as claimed in claim 14 or claim 15, further comprising at least one shim element engageable with the connector pin and/or pin support element of the or each metal-construction-beam connector system to permit levelling of stacked building-framework modules.
17.A building construction system as claimed in claim 16, further comprising a fastener-pin alignment jig engageable with the connector pin and/or pin support element of the or each metal-construction-beam connector system which is dimensioned to determine a number and/or size of the at least one shim element required for levelling.
18. A building construction system as claimed in any one of claims 14 to 17, further comprising a fastener-pin extractor device for extracting a fastener pin once received in the second fastener opening to allow for disassembly of the building construction system.
19. A building construction system as claimed in any one of claims 14 to 18, further comprising at least one secondary building-framework module engageable at least one of the plurality of metal-construction-beam connector systems
20.A building construction system as claimed in claim 19, wherein the or each secondary building-framework module includes one or more cantilevered tangs for location on said connector pin of at least one of the plurality of metal-construction-beam connector systems.
21.A modular building formed using a building construction system as claimed in any one of claims 14 to 20.
22. A method of providing an enhanced modular building construction process, the method comprising the steps of: a] at a location which is remote from a building-site location, pre-forming a plurality of building-framework modules; b] transporting the plurality of building-framework modules to the said building-site location; and c] interengaging the plurality of building-framework modules using the plurality of metal construction-beam connector systems via a plurality of horizontally insertable threadless fastener pins at interfaces of the building-framework modules.
23.A method as claimed in claim 22, wherein second fastener openings of the plurality of building-framework modules are aligned to permit insertion of the fastener pins from an external side thereof.
24. A method of improving the speed of disassembly of a modular building, the method comprising the steps of: a] using a fastener-pin extractor device, extracting the fastener pins of the metal construction-beam connector systems of a modular building as claimed in claim 21; and b] separating the plurality of building-framework modules from one another.
25. A connector system for interconnecting construction beams of buildings on-site, the connector system comprising: first and second mutually interengageable connector portions respectively mounted on adjacent construction beams to be interconnected, the first and second connector portions respectively having first and second fastener receivers, the first connector portion being receivably engageable along a first axis into the second connector portion to align the first and second fastener receivers; and a fastener pin insertable into the first and second fastener receivers to couple the first and second connector portions together along a second axis which is perpendicular to the first axis.