US20090049776A1 - Stable and efficient building system - Google Patents

Stable and efficient building system Download PDF

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Publication number
US20090049776A1
US20090049776A1 US11/843,655 US84365507A US2009049776A1 US 20090049776 A1 US20090049776 A1 US 20090049776A1 US 84365507 A US84365507 A US 84365507A US 2009049776 A1 US2009049776 A1 US 2009049776A1
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United States
Prior art keywords
modules
module
fitting
building
fitting surface
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Abandoned
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US11/843,655
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English (en)
Inventor
Matakii O'goshi Lim
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Individual
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Individual
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Application filed by Individual filed Critical Individual
Priority to US11/843,655 priority Critical patent/US20090049776A1/en
Priority to SG2012061941A priority patent/SG183752A1/en
Priority to AU2007355136A priority patent/AU2007355136A1/en
Priority to PCT/SG2007/000280 priority patent/WO2009025620A1/fr
Publication of US20090049776A1 publication Critical patent/US20090049776A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/06—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts

Definitions

  • the present invention relates generally to building construction. More particularly, the present invention relates to building modules for creating building structure.
  • cinder blocks are commonly used.
  • building construction begins with forming the foundation of the building and frame, with appropriate supports, such as columns and beams.
  • blocks are stacked and joined to form external walls, with windows and doorways as desired.
  • Mortar is used to join the blocks together.
  • the joining of blocks to form external walls required skilled labor, which increases production costs. Additionally, blocks are heavy, creating shipping and handling issues.
  • the present invention relates to building construction.
  • a building system comprises a plurality of different types of modules for forming external and internal walls of a building structure. Adjacent modules are interlocked by first and second fitting surfaces of respective adjacent modules.
  • the building system further comprises a fastening system for attaching first and second adjacent modules.
  • the fastening system comprises a fixing rod and wall fitting unit. One of the fitting surfaces of the first adjacent module is fitted with the wall fitting unit and the fixing rod is inserted through the second adjacent module.
  • a method of assembling a building system comprises providing a building structure base. Corner modules are mounted to the building structure base at corners of the building structure base. The method further comprises mating interconnecting types of building modules sequentially from the corner modules, wherein adjacent interconnecting types of building modules are mated by male and female fitting surfaces. Adjacent interconnecting types of building modules are attached with a fastening system.
  • the fastening system comprises a wall fitting unit mounted on the fitting surfaces of one of the modules and inserting a fixing rod through the other of the adjacent module and mating with the wall fitting unit.
  • a method of forming a module of a building system includes preparing a geopolymer mixture of the module.
  • the geopolymer mixture is inserted into an extrusion system.
  • the method further comprises the step of extruding a module from a mold, wherein the module comprises at least a first fitting surface for mating with a module with a second fitting surface.
  • the first fitting surface comprises one of a male or female surface and the second fitting surface comprises other of a male or female surface.
  • FIGS. 1 a - b show side and plan views of a generic module in accordance with one embodiment of the invention
  • FIGS. 2 a - b show female and male fitting surfaces in accordance with one embodiment of the invention
  • FIGS. 2 c - e show various detailed views of a module in accordance with one embodiment of the invention.
  • FIGS. 3 a - j show various types of modules of a building system in accordance with one embodiment of the invention
  • FIG. 4 illustrates a plan view of a module assembly in accordance with one embodiment of the invention
  • FIGS. 5 a - b show different views of mating modules in accordance with one embodiment of the invention.
  • FIGS. 6 a - c show fastening system for securing adjacent modules in accordance with one embodiment of the invention
  • FIG. 7 shows a corner module mated with middle modules in accordance with one embodiment of the invention.
  • FIGS. 8 a - b show a plan view and a detailed view of a building structure in accordance with one embodiment of the invention.
  • FIGS. 9 a - b show an attachment unit for corner modules in accordance with one embodiment of the invention.
  • FIGS. 9 c - d show base bolts in accordance with different embodiments of the invention. invention.
  • FIGS. 10 a - b show an attachment unit for middle modules in accordance with one embodiment of the invention.
  • FIGS. 11 a - b show a final attachment unit in accordance with one embodiment of the invention.
  • FIGS. 12 a - b show an assembled final middle module in accordance with one embodiment of the invention.
  • FIGS. 13 a - b show a pillar module in accordance with one embodiment of the invention.
  • FIGS. 14 a - d show a column assembly in accordance with one embodiment of the invention.
  • FIGS. 15 a - c show a window assembly in accordance with one embodiment of the invention.
  • FIGS. 16 a - b show a door frame in accordance with one embodiment of the invention.
  • FIGS. 17 a - b show a door frame assembly in accordance with one embodiment of the invention.
  • FIGS. 18-19 show a plumbing outlet in accordance with one embodiment of the invention.
  • FIGS. 20 and 21 show a garage door assembly in accordance in accordance with one embodiment of the invention
  • FIGS. 22 a - b and 23 a - b show a roof plate assembly in accordance with one embodiment of the invention
  • FIGS. 24 a - c show a roof plate assembly in accordance with another embodiment of the invention.
  • FIG. 25 shows a process for assembling a building structure in accordance with one embodiment of the invention.
  • FIG. 26 shows a process for fabricating building modules in accordance with one embodiment of the invention.
  • the building system comprises a plurality of building modules.
  • the modules serve as segments which can be easily interconnected or assembled to form a building structure.
  • the modules are used to form walls (internal and external) and serve as support or load bearing structures.
  • Various types of modules are provided to effect the desired building or floor plan.
  • the modules can be used to form single or multi-story building structures with the desired layout (e.g., shape, number and size of rooms).
  • the modules are easily attached using fasteners, such as bolts and wall fittings with nuts.
  • the modules can be easily adapted for use with conventional building structures.
  • the modules can be used with conventional bases and supports as well as roofing structures.
  • FIGS. 1 a - b show side and plan views of a generic module 100 in accordance with one embodiment of the invention.
  • the module comprises an elongated member comprising generally a rectangular cross-section with four sides or surfaces 102 - 105 . Providing modules with other geometric shaped cross-sections is also useful.
  • the elongated member comprises a length L, width W and thickness T.
  • W and T are equal to the length and thickness of a conventional cinder block.
  • W is about 0.30-0.41 m and T is about 0.2 m.
  • the length in one embodiment, is equal the height of a typical wall of the building structure.
  • L is about 2.7 m.
  • the members are provided in two different lengths, such as 2.6 and 2.7 m.
  • the different lengths correspond to the different heights for external and internal walls.
  • the longer length modules are used to form external walls while the shorter length modules are for internal walls.
  • the modules can also be cut to the desired length, for example, to accommodate door or window frames or different height ceilings. Providing modules with other values of T, W, and L are also useful.
  • At least one of the sides of the module comprises a smooth or flat surface.
  • the flat surface serves as, for example, either one of the surfaces of a building wall structure, such as inner, outer or end.
  • Some modules can have two, three or all flat surfaces.
  • the non-flat surfaces serve as fitting surfaces.
  • a fitting surface can be a male or female fitting surface.
  • modules with more than one fitting surfaces they can be male, female or a combination thereof. In the case where a module comprises four flat surfaces, no fitting surfaces are provided.
  • the module comprises at least one cavity 108 that extends the length of the module.
  • the module comprises two cavities that extend the length of the module.
  • the cavities can serve various functions.
  • the cavities can provide insulation or space for insulation, accommodate for utility or services, such as electrical wiring or plumbing as well as reducing weight of the modules.
  • the number of cavities depends on the width of the module.
  • the modules can have various unit widths, with each unit having one cavity. For example, in the case of modules having full and half widths, full width comprises two cavities while half width comprises one cavity. Other configurations of units and cavities are also useful.
  • FIG. 2 a shows female and male fitting surfaces 212 and 222 in accordance with one embodiment of the invention.
  • the female and male fitting surfaces interlock adjacent modules.
  • the female fitting surface comprises one or more receptacles 213 for receiving one or more protrusions 223 from the male fitting surface.
  • the male and female fitting surfaces of two adjacent modules create an opening or cavity 218 therebetween, as shown in FIG. 2 b.
  • the opening provides space to accommodate fasteners for fixing adjacent modules together.
  • a plane formed by the female fitting surface comprises recesses 213 and 216 .
  • the recesses extend the length of the module.
  • the female fitting surface comprises three recesses, one each located at the edges of the surface and one in the middle. Other arrangements are also useful.
  • the plane formed by the male fitting surface as indicated by the dotted line B-B, comprises first and second protrusions 223 corresponding to the mating recesses of the female surface.
  • the protrusions include a notch or a step 224 for mating with the recesses of the female surface.
  • the male fitting surface comprises a 226 recess between the protrusions.
  • the recesses 216 and 226 facilitate in creating the opening between two mated surfaces to accommodate, for example, fasteners. Other arrangements of the mating surfaces are also useful.
  • FIG. 2 c shows details of a module 200 in accordance with one embodiment of the invention.
  • the module comprises a full width module having first and second cavities 208 that extend its length.
  • the module includes smooth surfaces 202 and 204 along the width W which serves as walls.
  • the thickness T of the module are female and male fitting surfaces 212 and 222 . Measurements of various components of the module are provided. All measurements are in millimeters (mm).
  • FIGS. 2 d - e show 3-dimensional and fitting surface views in detail of a module 200 in accordance with one embodiment of the invention.
  • the module comprises, for example, a length L of 2.6 m with first and second fitting surfaces 212 and 222 .
  • a fitting surface ( 212 or 222 ) includes a top set of holes 265 and a bottom set of holes 266 .
  • a set of holes include four holes. Providing other number of holes per set or top and bottom sets with different numbers of holes is also useful.
  • holes are through holes, from one fitting surface to the other.
  • the top and bottom set of holes facilitate assembly to an adjacent module.
  • the holes can be fitted with a wall fitting unit or for a bolt to pass through.
  • the holes in one embodiment, are about 12 mm in diameter. Other hole sizes are also useful, depending on the fastener size or design.
  • the set of holes are provided 100 mm from the top or bottom surface, with succeeding holes at 100 mm intervals.
  • the bottom set of holes are provided 200 mm from the bottom surface at 100 mm intervals.
  • a fitting surface includes hole markings 268 located between the sets of holes. The hole markings provide locations for holes to be formed during assembly process if needed. The hole markings, in one embodiment, are spaced apart by 200 mm from holes or other hole markings. Other arrangements or configurations for placement of holes or hole markings are also useful.
  • the bottom of the fitting surface includes recess or routing 227 .
  • the recess serves to accommodate, for example, brackets to fix a module to the base of the building structure.
  • the recess for example, is about 10 mm deep. Other recess depths are also useful.
  • the modules comprise a geopolymer composite.
  • One example of the composition of the polymer composite is listed in Table 1. Other types of materials are also useful.
  • the modules can be formed of wood or cement.
  • the composite is preferably formed by extrusion. Other processes, such as casting, are also useful.
  • the technical data of the composite modules are listed in Table 2.
  • geopolymer composite produces modules which are lightweight and strong. For example, a panel having a size of 100 mm ⁇ 300 mm ⁇ 2600 mm weighs only about 39 kg. Additionally, the geopolymer composite modules are fire retardant and resistant to moisture.
  • FIGS. 3 a - j show plan views of various types of building modules in accordance with one embodiment of the invention.
  • the modules are configured with first and second sizes.
  • the modules are either full or half size. Providing modules with more or less number of sizes are also useful.
  • a corner module 330 a is shown.
  • the corner module is used to create corners or bends in the building structure.
  • the corner module comprises a rectangular shape having first and second adjacent flat surfaces 305 a - b and first and second adjacent fitting surfaces 312 and 322 .
  • the flat surfaces as shown, are perpendicular or form a 90° angle.
  • the fitting surfaces are perpendicular.
  • the fitting surfaces are configured to mate with other modules to create perpendicular walls.
  • the first surface comprises a female fitting surface and the second fitting surface comprises a male fitting surface.
  • the corner module comprises a half size module with one cavity 318 .
  • the female fitting surface is mated to a male fitting surface of a first adjacent module; the male fitting surface is mated to a female fitting surface of a second adjacent module.
  • Other configurations such as shape and size of the module or number, angle, or type of fitting surfaces as well as number of flat surfaces are also useful.
  • more than two fitting surfaces can be provided to create an intersection having more than two walls.
  • a T-connection module 330 b is shown.
  • the T-connection module is used to join a wall with another in the building structure.
  • the T-connection module comprises a half size rectangular shaped module with one cavity 318 , first, second and third fitting surfaces 322 , 312 a and 312 b and a flat surface 305 .
  • the first and second fitting surfaces are located on opposing sides of the module while the third fitting surface is perpendicular to the other fitting surfaces.
  • one of the first and second surfaces comprises a female fitting surface and the other comprises a male fitting surface.
  • the first surface comprises a male fitting surface and the second comprises a female fitting surface.
  • the third fitting surface comprises a female fitting surface, forming a female-type T-connection module.
  • a T-shaped wall structure is formed. As such, the walls are joined at a 90° angle.
  • T-connection modules having other configurations, such as shape and size of the module or number, angle, or type of fitting surfaces as well as number of flat surfaces are also useful.
  • the T-connection module comprises a full size rectangular shaped module with two cavities 318 a - b, first, second and third fitting surfaces 322 a, 312 and 322 b and a flat surface 305 .
  • the first and second fitting surfaces are located on opposing sides of the module while the third fitting surface is perpendicular to the other fitting surfaces. Since the module is a full size module, the third fitting surface comprises fitting and smooth 306 surfaces, with the fitting surface located at one side of the module. Providing the fitting surface in the middle of the module is also useful.
  • one of the first and second surfaces comprises a female fitting surface and the other comprises a male fitting surface.
  • the first surface comprises a male fitting surface and the second comprises a female fitting surface.
  • the third fitting surface comprises a male fitting surface, forming a male-type T-connection module.
  • a T-shaped wall structure is formed.
  • the walls are joined at a 90° angle.
  • Other configurations, such as shape and size of the module or number, angle, or type of fitting surfaces as well as number of flat surfaces are also useful.
  • the third fitting surfaces can include more than one fitting surfaces formed at an angle other than 90°.
  • FIG. 3 d An end module 330 d in accordance with one embodiment is shown in FIG. 3 d.
  • the end module comprises a half size rectangular shaped module with a cavity 318 .
  • the end module comprises a fitting surface 312 on one side while the remaining sides 305 a - c are flat surfaces.
  • the end module serves to form the end of a wall.
  • the fitting surface as shown, comprises a female fitting surface.
  • Providing a male fitting surface 322 as shown in FIG. 3 f, is also useful.
  • end modules can be full size end modules with two cavities 318 a - b with either a male fitting surface 322 or female fitting surface 312 .
  • Other configurations, such as angle of the fitting surfaces to form bends at the end of the wall is also useful.
  • FIG. 3 h shows a middle module 330 h in accordance with one embodiment of the invention.
  • the middle module comprises a half size rectangular shaped module with a cavity 318 . Providing a full size module 330 i having two cavities 318 a - b, as shown in FIG. 3 i, or other sizes is also useful.
  • the middle module comprises first and second fitting surfaces 312 and 322 on opposing sides while the remaining sides 305 a - b are flat surfaces.
  • the middle module is used to connect other modules on the fitting surfaces to form, for example, middle section of the wall.
  • the first fitting surface comprises a female fitting surface and the second fitting surface comprises a male fitting surface.
  • Other configurations, such as shape and size of the module or type of fitting surfaces are also useful.
  • the flat surfaces can include an angle to create bends in the wall or the fitting surfaces can be of the same type.
  • a pillar module 330 j in accordance with one embodiment is shown in FIG. 3 j.
  • the pillar module comprises a full size rectangular shaped module with two cavities 318 a - b. Providing pillar modules of other sizes is also useful.
  • the pillar end module comprises flat surfaces 305 a - d. Other configurations, such as shape and size of the module, are also useful. For example, the flat surfaces can include an angle.
  • FIG. 4 illustrates a plan view of a module assembly 400 of various modules in accordance with one embodiment of the invention.
  • a corner module 430 a is provided.
  • Various modules can be mated together along a first direction X with the corner module to form a first wall 450 of the module assembly.
  • the fitting surface of the corner module in the first direction comprises a female mating surface.
  • a middle module 430 i, male-type T-connection module 430 c and full size male-type end module 430 g are mated sequentially to the corner module in the X direction to form a first wall 450 of the module assembly.
  • Various modules can be mated together along a second direction Y with the male-type T-connection module.
  • middle module 430 i and female-type half size end module 430 d are sequentially mated to the male-type T-connection module 430 c to form a second wall 452 of the module assembly.
  • Other combinations of modules can also be used to form the first and second walls, as desired.
  • a third wall 454 is formed by various modules sequentially mated to the corner module in the Y direction.
  • the mating surface of the corner module in the Y direction comprises a male fitting surface.
  • a full size middle module 430 i, half size middle module 430 h, half size female-type T-connection module 430 b, two middle modules 430 i and a full size female-type end module 430 e are sequentially connected to the corner module in the Y direction.
  • a fourth wall 456 is formed along the X direction by mating various modules to the half size female-type T-connection module 430 b.
  • a middle module 430 i and a half size male end module 430 f are sequentially mated to the female-type T-connection module 430 b.
  • the second and fourth walls do not merge. Merging the second and fourth wall by, for example, a corner module can form an enclosed room 440 .
  • column modules structural support of the building structure is provided by column modules. As shown, a full size column module 430 j is mated to one of the middle modules 430 i 1 on the third wall. Column modules can be mated to the walls or as stand alone columns as needed, depending on for example design requirements.
  • FIGS. 5 a - b show different views of securing modules in accordance with one embodiment of the invention.
  • first and second modules 530 1 and 530 2 are provided.
  • the male fitting surface 522 1 of the first module is mated to the female fitting surface 512 2 of the second module.
  • the modules have top holes 565 and bottom holes 566 on the fitting surfaces.
  • the holes are also provided in the internal surface 514 which separates the cavities.
  • 4 top holes and 4 bottom holes are provided for the modules. Providing other number of holes is also useful.
  • the top and bottom holes are located on the fitting surface such that the top and bottom of the module can be interchangeable.
  • a fastening system is used to secure the two modules together.
  • the fastening system comprises a fixing rod 570 and a wall fitting unit 571 .
  • a fastening system can be used for the top and bottom portion.
  • a wall fitting unit is fitted into one of the top and bottom holes on the female fitting surface of the second module.
  • fixing rods are inserted through one of the top and bottom holes of the female fitting surface 512 1 of the first module and screwed into the wall fitting unit.
  • Other configurations such as mounting the wall fitting unit to a male fitting surface of one module and inserting the fixing rod through the male fitting surface of another are also useful.
  • FIG. 6 a shows a fastening system in accordance with one embodiment of the invention.
  • FIGS. 6 b - c show a wall fitting unit in greater detail in accordance with one embodiment of the invention.
  • the fastening system comprises a fixing rod 570 and a wall fitting unit 571 .
  • Male thread is provided on the fixing rod which is mated to female thread on the wall fitting unit.
  • the size of the fastening system is sufficient to secure the modules.
  • the fixing rod is formed from galvanized steel having a diameter of 8 mm with M6 thread on one end and a hex head and shoulder on the other while the wall fitting unit includes M6 internal thread and an outer diameter of 11.5 mm. Other materials or dimensions are also useful.
  • the wall fitting unit in one embodiment comprises head, body and end portions 674 - 676 .
  • the head portion comprises an opening for the fixing rod to pass through and the end portion comprises female thread which mates with the male thread of the fixing rod.
  • the body portion comprises fingers 679 .
  • the body portion comprises a length L greater than the thickness of the fitting surface.
  • the threaded portion is about the thickness of the fitting surface for fitting thereto while the finger portion extends beyond the fitting surface.
  • FIG. 7 shows securing of modules in accordance with one embodiment of the invention.
  • a corner module 730 1 includes female and male fitting surfaces 712 1 and 722 1 .
  • Wall fitting units 771 are inserted into top and bottom holes on the fitting surfaces.
  • Male fitting surface 722 2 of, for example, a first middle module 730 2 is mated to the female fitting surface of the corner module;
  • female fitting surface 712 3 of, for example, a second middle module 730 3 is mated to the male fitting surface of the corner module.
  • fixing rods 770 are inserted through the modules and mated with the wall fitting units.
  • fastening systems are provided at the top and bottom parts of the modules. Other configurations of fastening systems are also useful.
  • middle modules as well as other modules can be connected therefrom to form walls in the X and Y directions to create the desired layout.
  • FIG. 8 a shows a plan view of a building structure in accordance with one embodiment of the invention.
  • a base 890 is provided on which modules are assembled.
  • the base for example, comprises a slab of concrete having the shape of the perimeter of the building structure.
  • the base can be formed by conventional techniques.
  • Modules 830 are fixed to the perimeter of the base, as indicated by the dotted lines, forming the internal space of the building structure. Other types of materials or shapes are also useful.
  • the slab can be designed to extend beyond the outer walls of the building structure.
  • the base comprises a step 891 .
  • Modules rest on a base 891 a of the step while a back 891 b of the step provides additional vertical support and serving as a barrier from external elements.
  • the longer modules e.g., 2.7 m
  • the shorter modules e.g., 2.6 m
  • the width of the step is equal to about the width W of the module while the height can be about 100 mm.
  • a sealant can be applied to the modules in the step portion to prevent penetration of water or other environmental elements.
  • the modules can easily be adapted to use for multi-level building structures, including basements.
  • multi-level building structures including basements.
  • conventional foundation and building support structures can be used to providing the framework to which the modules are installed.
  • FIGS. 9 a - b show an attachment unit in accordance with one embodiment of the invention.
  • the attachment unit is used to mount or fix a module to the base.
  • the attachment unit comprises a support bracket 844 .
  • the support bracket for example, comprises an L-shaped bracket with a back and foot portions 847 a - b.
  • the bracket for example, comprises galvanized steel of about 5 mm thick. Other materials or thicknesses are also useful.
  • the back portion is attached to a fitting surface of the module while the foot is fixed to the base.
  • a plurality of openings 848 a - b are provided on the foot and back portions to facilitate attaching the support bracket to the module and base.
  • the back comprises four vertical slotted opening corresponding to the four holes on the bottom of the fitting surface and a circular opening on the foot portion.
  • the slotted openings allow for leveling adjustments to be made due to, for example, variations in the base. Providing the back and foot portions with other number or types of openings is also useful.
  • First wall fittings 870 1 for attaching the support bracket are installed into holes in the fitting surface.
  • wall fittings are inserted into first and last holes of the set of plurality of holes in the lower portion of the module.
  • the first and fourth holes of the set of plurality of holes are fitted with wall fittings.
  • a second wall fitting 870 2 is also fitted into one of the holes between the first and last holes of the set of plurality of holes, for example, either the second or third hole.
  • the second wall fitting is mated with a fixing rod for securing an adjacent module.
  • First bolts 873 are mated to the first wall fittings through the first and fourth vertical slotted openings to attach the support bracket to the fitting surface of the module.
  • a second bolt 881 is inserted through the first opening in the support bracket for attaching the module to the base.
  • the second bolt comprises a base bolt.
  • the base bolt for example, anchors the module to the base.
  • the second bolt for example, comprises a DynaboltTM system manufactured by Ramset.
  • FIG. 9 c shows a DynaboltTM system 881 a.
  • the DynaboltTM can be installed by inserting it into a hole 885 drilled into the base 890 . As a bolt 889 is tightened, fingers 886 expand to anchor the DynaboltTM in place.
  • the second bolt comprises a ChemSetTM system 881 b manufactured by Ramset as shown in FIG. 9 d.
  • the ChemSetTM can be installed by drilling a hole 885 into the base 890 .
  • the hole is filled with the ChemSetTM adhesive 887 and inserting a bolt 888 into the hole.
  • the bolt is permanently fixed to the base, anchoring the module thereto.
  • the second bolt can be formed from galvanized steel with an outside diameter of 10 mm. Other techniques for anchoring the module are also useful.
  • an attachment unit is provided at the bottom of each fitting surface, for example, female and male fitting surfaces 812 and 822 .
  • Attachment units can also be provided for the middle modules, shown in FIG. 10 a to provide additional structural stability.
  • the attachment unit can be mounted onto a fitting surface 822 of a middle module 830 1 after being attached to an adjacent module 830 2 .
  • the attachment unit is provided for every third to sixth middle module. Providing other arrangement of attachment units for middle modules is also useful and may depend on design requirements. For example, attachment units can be provided for every one, every other middle module, or other number of middle module is also useful. As shown, the attachment unit is mounted onto a male fitting surface.
  • a recess 827 is provided at the bottom of the fitting surface, as shown in FIG. 10 b.
  • the recess can also be provided on the top of the fitting surface, making the top and bottom of the modules interchangeable.
  • FIGS. 11 a - b show a final attachment unit in accordance with one embodiment of the invention.
  • the attachment unit is used to fix or mate the bottom part of the last module of a series of modules. For example, the end module of a wall or the last of the middle modules to be assembled to form a wall. This is because fixing rods are not able to be used to attach these modules.
  • the final attachment unit in one embodiment, comprises a final support bracket 854 .
  • the support bracket for example, comprises substantially an L-shaped bracket with back and foot portions 857 a - b.
  • the back portion is attached to the bottom of a fitting surface of the module.
  • a plurality of openings 856 are provided on the back portion to facilitate attaching the support bracket to the module.
  • the back portion comprises four vertical slotted openings corresponding to the four holes on the bottom of the fitting surface.
  • the slotted openings allow for leveling adjustments to be made due to, for example, variations in the base. Providing the back portion with other number or types of openings is also useful.
  • First wall fittings 870 1 for attaching the support bracket are installed into holes in the fitting surface.
  • the first wall fittings are inserted into first and last holes of the set of plurality of holes in the lower portion of the module.
  • the first and fourth holes of the set of plurality of holes are fitted with wall fittings.
  • a second wall fitting 870 2 is also fitted into one of the holes between the first and last holes of the set of plurality of holes, for example, either the second or third hole.
  • a second wall fitting (not shown) is also provided for one of the holes in the top portion of the module.
  • First bolts 873 are mated to the first wall fittings through the first and fourth vertical slotted openings to attach the support bracket to the fitting surface of the module.
  • the foot portion extends from the bottom of the back portion to form a hook or latching surface.
  • the distance D between the latching surface and back should allow the fitting surface to fit and be held in place.
  • D provides a snug fit for the fitting surface.
  • D is equal to the thickness of the fitting surface.
  • FIG. 12 a shows a final middle module being assembled in a wall.
  • the wall includes first and second portions 829 a - b.
  • the portions include modules 830 1 and 830 2 such as middle modules extending from, for example, corner modules, T-modules or a combination thereof
  • the final middle module 830 3 is inserted into the opening 827 between the two wall portions from the top, with the fitting surfaces mating.
  • the male fitting surface 822 of the final module is mated to the female fitting surface of the first wall portion and the female fitting surface 812 of the final middle module is mated to the male fitting surface of the second wall portion.
  • final attachment units 854 hold it in place.
  • Bolts 872 are mated to respective wall fittings 871 2 in the top part of the fitting surfaces of the modules adjacent to the final module 830 3 , as shown in FIG. 12 b.
  • End modules can be attached to an adjacent module in a similar manner using a final attachment unit at the bottom and bolts and fittings for the top.
  • FIGS. 13 a - b illustrate a pillar module 332 in accordance with one embodiment of the invention.
  • the pillar module is attached to a module, for example, a middle module 330 , on a wall portion 329 .
  • pillar attachment units are used.
  • four pillar attachment units are used, two for the upper portion and two for the lower portion of the module.
  • a pillar attachment unit comprises a pillar support bracket 364 .
  • the pillar support bracket includes a flat base portion 367 a and a stepped head portion 367 b. Holes 348 are provided on the base portion.
  • first and second holes are provided near the ends of the base portion. Providing other hole configurations is also useful.
  • pillar attachment units are mounted onto a wall module to create a male-type mating surface for the pillar module.
  • the pillar module is provided with slots 369 corresponding to the pillar attachment units, creating a female-type mating surface.
  • Other configuration of mating surfaces such as providing the pillar module with a male-type mating surface while the wall module is provided with a female-type mating surface or a combination thereof (e.g., each module is provided with both male-type and female-type mating surfaces), are also useful.
  • wall fittings 371 are installed into holes provided onto the male-type mating surface.
  • the holes for example, can be provided by drilling the male-type mating surface.
  • Bolts 372 are inserted through the holes of the base and mated to the wall fittings to securely mount the support bracket onto the mating surface.
  • the pillar attachment unit is mated to the wall module with the head portion facing upwards. Mounting the pillar attachment unit with the head portion facing downwards (e.g., pillar module having male-type mating surface) is also useful.
  • pillar module comprises a height which is less than the height of the wall module. This is to accommodate the difference between the step and the flooring.
  • the pillar module for example, is a load bearing module which aids in the construction of multiple stories or to act as an anchor point for walls. As such, pillar modules can be provided where needed in the building structure.
  • FIGS. 14 a - d show a column assembly 439 in accordance with one embodiment of the invention.
  • the column assembly provides load bearing function and aids in general construction of the building structure, such as roof and additional floors.
  • Column module assemblies can be provided within the building structure as needed.
  • the column assembly comprises a column support 435 and first and second column modules 433 and 434 .
  • the column support can be formed from steel and is capable of supporting the desired load.
  • the column support comprises galvanized steel.
  • the column support as shown, comprises first and second sub-columns 437 formed on a base plate 436 .
  • the sub-columns fit within the cavities 418 a - b of one of the pillar modules.
  • the sub-columns are 50 mm ⁇ 50 mm ⁇ 4 mm square hollow sections with 5 mm base plate. Providing column support with other number of sub-columns is also useful, for example, depending on the size or number of cavities in the module.
  • the base of the column support is mounted onto the base of the building structure with, for example, base bolts through holes 438 .
  • the holes are arranged such that two are located near the edge on one side of the base and another two are located near the middle on an opposing side of the base. Other arrangements of holes or other techniques for mounting the column support to the base are also useful.
  • One of the pillar modules is provided with the male-type mating surface 464 which include pillar attachment units while the other comprises a female-type mating surface 466 with slotted openings, as described in, for example, FIGS. 13 a - b.
  • the column support is inserted in the cavities of the male-type pillar module. Once the column is within the cavities of the male-type pillar module, wall fittings 471 are installed in holes in the module and the column support, as shown in FIG. 14 c. Bolts are inserted through holes in the support bracket and tightened, securing the module to the column support.
  • the pillar attachment units are formed from, for example, 3 mm thick galvanized steel. Other materials or thicknesses are also useful.
  • recesses 418 are formed in the bottom of the pillar module 433 , as shown in FIG. 14 d.
  • the female-type pillar module is then mated to the male-type module, completing the column assembly, as illustrated by FIG. 14 b.
  • FIGS. 15 a - c show a window frame 582 of a building system in accordance with one embodiment of the invention.
  • the window frame in one embodiment, comprises a plurality of capping layers 583 .
  • Various types of materials can be used to form the capping layers.
  • steel, tin, wood, plastic or polymer can be used. Other types of materials are also useful.
  • the capping layer provides a surface which is mated to the modules' fitting surfaces or end surfaces.
  • the capping layers can joined together.
  • the window frame comprises a rectangular shape with a height H, width W and thickness T formed by joining four straight capping layers.
  • the capping layers could be joined using mitre joints.
  • Other window frame shapes or techniques for joining the capping layers are also useful.
  • the window frame can be formed from a single molded piece of material.
  • W is selected to be a multiple of the smallest size unit of the modules, for example, half size (1 cavity).
  • the width W can also be of other dimensions.
  • W can be a multiple of full size modules or other dimensions.
  • the capping layer comprises a U-shaped cross section.
  • the top surface 584 of the capping layer includes a mounting surface 541 a with a beveled edge 541 b.
  • a window 549 is mounted onto the mounting surface.
  • window mounts 543 can be used.
  • window mounts are attached to the frame by, for example, fasteners such as rivets or screws.
  • the window can be fixed to the mounts by rivets.
  • Other techniques for mounting the window to the frame are also useful.
  • the window frame is arranged such that the beveled edge faces outward.
  • a bottom surface 547 is mated to the modules.
  • a bottom surface of the capping layer is mated to a middle module 529 as shown in FIG. 15 c.
  • the capping layer can be fit to secure the modules.
  • the frame can be attached to the modules by adhesive. Other techniques for mounting the frame to the modules are also useful.
  • a wall 529 having an opening 525 is provided.
  • the opening for example, is formed by cutting modules in portion 528 to a length equal to the height of the bottom of the window.
  • the width of portion 528 corresponds to the width of the window frame.
  • the width of portion 528 is equal to the width of X full size modules, where X is a whole number. Other values of X are also useful, including non-whole numbers.
  • FIGS. 16 a - b show a door frame 661 for the building system in accordance with one embodiment of the invention.
  • the door frame in one embodiment, comprises a plurality of frame rails 663 .
  • the frame rails are formed from steel. Other types of materials are also useful. For example, tin, wood, plastic or polymer can also be used.
  • the door frame comprises a rectangular shape with an open side, having a height H, width W and thickness T formed by joining three straight frame rails layers.
  • the frame rails could be joined using mitre joints. Joining can be achieved by, for example, welding or adhesives.
  • the door frame can be formed from a single molded piece of material. Other door frame shapes or techniques for joining the frame rails are also useful.
  • W is selected to be a multiple of the smallest size unit of the modules, for example, half size (1 cavity).
  • the width W can also be of other dimensions.
  • W can be a multiple of full size modules or other dimensions, including non-multiples of smallest size unit.
  • the frame rails comprise a U-shaped cross section.
  • the U-shaped cross section provides a surface 662 , as indicated by dotted lines, which is mated to the modules fitting surfaces or end surfaces.
  • a recess 665 is provided in the fitting surface.
  • FIGS. 17 a - b show different views of a door frame assembly in accordance with one embodiment of the invention.
  • the width of the opening corresponds to the width of the door frame.
  • the wall sections are formed by, for example, a plurality of middle sections coupled to corner or T-modules. Other wall configurations are also useful.
  • the door frame is installed by sliding it from the top through the edge of the wall sections.
  • Door fitting bracket assemblies 773 are provided on the fitting surfaces of the last middle modules 730 of the wall sections adjacent to the opening. In one embodiment, each fitting surface is provided with three door fitting brackets. Other door fitting bracket configurations and number are also useful.
  • a door fitting bracket assembly comprises a door bracket.
  • the door bracket comprises a central portion 776 with an opening. One opposing sides of the central portion are winged portions 775 .
  • a wall fitting 771 is installed into the fitting surface.
  • a bolt 772 is inserted through the opening in the central portion and mated to the wall fitting.
  • the profile of the bracket forms a male profile which is compatible to the female profile of the frame rail to securely hold the door frame in position when installed into the wall.
  • FIGS. 18-19 show plumbing outlet in accordance with one embodiment of the invention.
  • a wall 829 is shown.
  • the wall is formed by, for example, a plurality of modules. Piping for plumbing runs through the modules.
  • plumbing plugs 695 are provided to access the piping for plumbing outlets.
  • Plumbing plugs for example, comprises PVC plugs. Other types of plugs are also useful. The plugs are installed into the module to provide access to the pipes.
  • the piping 694 for plumbing are preferably run through the cavities 918 of the modules 930 .
  • Plugs 695 are installed into the module, providing access to the pipes.
  • the plugs include a tapered profile to aid in the tiling process.
  • a plumbing outlet 697 is mounted on the module through the plug and mated to the pipes.
  • the modules are formed from water resistant material, such as a polymer composite. Other type s of water resistant materials are also useful. As such, there are no restrictions to where wet areas can be installed.
  • FIGS. 20-21 show a garage door assembly 256 in accordance with one embodiment of the invention.
  • the garage door assembly is installed into a wall having first and second portions 229 a - b with an opening 260 therebetween.
  • the wall portions comprise a series of connected full size middle modules.
  • the last module on the wall portions adjacent to the opening are cut to the height of about the top of the garage door.
  • Other configurations of the wall portions are also useful.
  • the opening comprises a width W corresponding to the width of the garage door.
  • W is selected to be a multiple of the smallest size unit of the modules, for example, half size (1 cavity).
  • the width W can also be of other dimensions.
  • W can be a multiple of full size modules or other dimensions, including non-multiples of smallest size unit.
  • the garage door assembly in one embodiment, comprises first and second side brackets 257 a attached to ends of a u-channel rail 257 b.
  • the side brackets are attached to mating surfaces of fitting surfaces of penultimate modules exposed by cutting of the end modules adjacent to the opening.
  • the side brackets include a hooked top portion for hanging over the top of the fitting surface of a module. To accommodate the hooked top portion, the top of the modules can be recessed.
  • the garage door assembly is formed, for example, from 4 mm thick galvanized steel. Bolts are inserted through holes in the brackets and mated with wall fittings on the fitting surface to securely attach the garage assembly to the wall.
  • Middle modules cut to appropriate size are disposed on the u-channel railing, forming a wall portion 221 on the top of the garage door.
  • Other arrangements of installing the garage door assembly are also useful.
  • the fitting surfaces of the end modules below the garage door assembly are fitted with capping layers 583 , forming a garage door opening having a width W and height H corresponding to the size of the garage door.
  • the garage door assembly includes side brackets 257 a attached to the u-channel rail 257 b.
  • hooks 258 are provided on the surface of the u-channel railing.
  • the hooks are, for example, equally spaced apart.
  • the hooks are located on the railing corresponding to the cavity of a module.
  • the hooks are J-shaped hooks as shown in FIG. 21 . Other types and shapes of hooks are also useful.
  • FIGS. 22 a - b show a roof plate assembly in accordance with one embodiment of the invention.
  • a roof plate 250 is provided over the top of the garage.
  • the roof plate is securely attached to the top of the modules.
  • the roof plate serves as a base to which a roof frame is attached.
  • the roof plate is attached to the garage assembly 256 by roof plate fasteners 251 .
  • the roof plate fasteners for example, couple the plate to the hooks on the u-channel rail 257 b.
  • FIGS. 23 a - b show a roof plate assembly in accordance with one embodiment of the invention in greater detail.
  • the roof plate is attached to the garage door assembly 256 with roof plate fasteners 251 .
  • the roof plate fastener comprises a threaded hook 252 .
  • the threaded hook for example, comprises 6 mm diameter galvanized steel with M6 thread on one end.
  • the hook 252 is mated to the hook 258 on the u-channel railing, with the threaded portion passing through holes in the roof plate and secured by a washer and bolt 253 .
  • FIGS. 24 a - c show a roof plate assembly in accordance with another embodiment of the invention.
  • the roof plate is attached to a wall 239 of the building structure.
  • the roof plate is attached, in one embodiment, to the fixing rods 270 connecting modules of the wall with a roof plate fastener 251 .
  • the roof plate fastener comprises a threaded hook 252 , as previously described.
  • the hook is mated to the fixing rod, with the threaded portion passing through holes in the roof plate and secured by a washer and bolt 253 .
  • modules to which the treaded hook is attached are anchored to the base by base bolts.
  • the base bolts comprise ChemSetTM base bolts.
  • the roof plate enhances stability, for example, enabling the building structure to withstand cyclone type environment.
  • the roof plate is directly coupled to the base.
  • a rod with threads on both ends is used.
  • One end of the rod is coupled to a base bolt; such as a ChemSetTM base bolt.
  • the head of the base bolt includes a threaded opening for accommodating the rod.
  • the other end of the rod is coupled to the roof plate.
  • FIG. 25 shows a process for assembling a building in accordance with one embodiment of the invention.
  • the assembly process commences by forming the base or foundation at step 910 .
  • the base for example serves as a foundation for the modules to attach.
  • the base for example, comprises concrete.
  • Conventional processes can be employed to form the base.
  • the footing on which the modules are attached are formed.
  • the slab is formed.
  • Other types of foundations are also useful.
  • the house can include a basement. In such case, the basement foundation and structure is formed followed by the footing.
  • the flooring can then be formed with appropriate structural support formed.
  • the external walls are formed.
  • the corners of the external walls are first installed.
  • the corner modules are attached to the footing using support brackets.
  • the walls are formed.
  • the walls can be formed by installing and attaching middle modules or T-modules as appropriate.
  • the modules are installed from the corner modules toward the middle of the wall. Windows, doors, and pillars are installed as designed.
  • Internal walls are formed at step 930 .
  • corner modules are first installed followed by intermediate modules, such as middle or T-modules. Doors and pillars are installed as designed.
  • step 940 services (e.g., electrical and plumbing services) are installed at step 940 . If additional floors are included in the building structure, the process returns to step 910 to form the footing and flooring for the next floor. Stairways, for example, interconnecting the floors can be formed. Once all floors are completed, the process continues to form roof structure at stop 960 . External walls can be rendered. For example, textured paints can be used. Other types of rendering can also be useful. Internal portions of the building structure are also finished, completing the building structure. For example, gypsum boards can be installed and painted. A useful type of wall finish comprises an acrylic textured finish known as DuluxTM.
  • FIG. 26 shows a process for forming modules in accordance with one embodiment of the invention.
  • An extrusion machine can be provided for the different types of modules, for example, to have the desired form, including size and fitting surfaces.
  • the different output molds can be provided to form different types of modules.
  • Raw materials are prepared at step 904 for extrusion. Additional preparation steps include storage, buffering and feeding at step 908 , batching and weighing at step 914 and mixing at step 918 .
  • a pre-extrusion is performed at step 924 followed by extrusion at step 928 .
  • the extruded material is pre-cut to the desired size, forming intermediate modules at step 934 .
  • the pre-cut modules are stacked and pre-cured at steps 938 and 944 .
  • the pre-cut modules are de-stacked and processed at step 948 .
  • the pre-cut modules are cut to the final length L at step 954 , holes drilled at step 958 and recess formed by routing at step 964 .
  • the prepared modules are stacked and cured for shipping at step 968 .

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)
  • Joining Of Building Structures In Genera (AREA)
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AU2007355136A AU2007355136A1 (en) 2007-08-23 2007-08-28 Stable and efficient building system
PCT/SG2007/000280 WO2009025620A1 (fr) 2007-08-23 2007-08-28 Système de construction stable et efficace

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WO2009025620A1 (fr) 2009-02-26
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