WO2003078748A1

WO2003078748A1 - Floor construction, modular building with such a floor constructioin and method for production of a floor construction

Info

Publication number: WO2003078748A1
Application number: PCT/SE2003/000313
Authority: WO
Inventors: Peter Broberg
Original assignee: Bopa Ab
Priority date: 2002-02-27
Filing date: 2003-02-26
Publication date: 2003-09-25
Also published as: EP1485543A1; AU2003220779A1; AU2003217096A1; WO2003093593A1; SE521286C2; NO20043552L; SE0200607D0; SE0200607L; US20050210762A1

Abstract

The invention relates to a floor construction, comprising a plurality of loadbearing steel bars (24), preferably sheet metal profiles, and one or more superposed panel elements (17), such as gypsum boards. The panel elements (17) are supported by the steel bars (24) via (i) at least one trapezoidal metal sheet (16) or the like, which defines an intermediate horizontal plane of the floor construction and which forms a plurality of ducts (133) for laying of installation components (138), such as lines and pipes, in the intermediate horizontal plane; and (ii) a plurality of spacers (132) which are distributed in the intermediate horizontal plane in at least one zone (IZ-1; IZ2), termed installation zone, at the side of the trapezoidal metal sheet (16) where said ducts (133) open, and which spacers (138) horizontally between them define spaces in which said installation components (138) are adapted to be laid also in other directions (139) than the direction of the ducts (133) of the trapezoidal metal sheet (16). The invention also relates to a method of manufacturing a floor construction and a modular building comprising such a construction.

Description

Floor construction, modular building with such a floor construction and method for production of a floor construction.

Field of the Invention

The invention relates generally to the technical field of floor constructions, more specifically to floor constructions for forming "installation floors", i.e. floor constructions in which installation components such as pipes and lines are arranged.

The invention has been provided specifically for use in modular buildings made by lightweight construction engineering and will be described in association therewith. A preferred modular building and prefabricated volume modules included therein are the subject matter of an international patent application (No. PCT/SE03/00303) filed on the same date and with the same applicant as the present application.

Background Art

WO 91/05118 discloses a modular building comprising a skeleton or frame construction consisting of vertical frame columns and horizontal bars and beams which are joined with each other in a torsionally rigid manner in joints of the frame construction. The larger the building, the higher construction requirements are placed on the rigidity of the frame of the building. Both horizontal forces (wind forces) and vertical forces (payloads and dead weights) are transferred to the frame construction.

A drawback of this prior-art building according to WO 91/05118 is precisely the existence of and requirements for such torsionally rigid joints. It is a major technical problem to satisfy all the rigidity requirements that are placed on a modular building, especially the torsionally rigid joints where different materials, forces and functions meet. Joints belong to the most difficult problems in construction engineering. The time required at the building site for forming the joints is also an important factor.

SE 9404111-8, which concerns a solution to the above problems, discloses a modular multistorey building which, with respect to force take-up, is divided into on the one hand an inner zone, which takes up vertical forces and comprises frame columns with the volume modules suspended therefrom on several floor levels and which essentially does not take up any lateral forces acting on the build- ing and, on the other hand, a fagade zone, which is arranged immediately outside the inner zone and adapted to take up lateral forces for lateral stabilisation of the inner zone and hence the entire building. The fagade zone comprises a plurality of fagade panel elements dis- tributed along the outside of the inner zone and vertically oriented perpendicular to the fagade of the building. In this solution, use is not made of horizontal beams as included in prior-art frame constructions. The payloads and dead weights of the modules are distributed over and taken up by the columns in the inner zone while most of the horizontal wind forces acting on the building are taken up by the fagade panel elements arranged perpendicular to the fagade in the fagade zone outside the inner zone . While the problem of torsionally rigid joints is at least partially solved in SE 9404111-8, a new problem arises, viz. that the required size and cost of the horizontally stabilising fagade zone rapidly increase as the number of floors in the building increases. Besides, the solution involving a special fagade zone is in itself not quite satisfactory.

The above problems are objects of the invention in the above-mentioned co-pending international patent application. A major problem in most construction systems is the conflict between constructions and installations. Installation of supply systems makes it necessary to lay linear components such as pipes, cables, lines, ducts etc. (below referred to as "installation components") in continuous systems all over the building. These installation systems are horizontal as well as vertical and must cross building constructions such as beams, columns, walls, floors and ceiling panels. Generally, installation components all over the building are to be collected in tube paths and extend to/from a supply centre.

The constructions in lightweight construction sys- tems are often minimised, with no or just a limited possibility of making holes for installation components. In steel buildings, the constructions are also difficult to break through.

Therefore, there is a need for a canalising prin- ciple that minimises or eliminates the number of points where the constructions are an obstacle to the laying of pipe and line components.

An object of the present invention is to obviate or at least reduce this problem. The floor construction according to the invention is particularly suited for use in combination with the lightweight construction engineering that is the subject matter of the above- mentioned co-pending international patent application, but is useful also for other types of buildings with loadbearing steel floor bars.

Summary of the Invention

According to a first aspect of the invention, there is provided a floor construction, comprising a plurality of loadbearing steel bars, preferably sheet metal profiles, and one or more superposed panel elements, such as gypsum boards. The floor construction according to the invention is characterised in that the panel elements are supported by the steel bars via: (i) at least one trapezoidal metal sheet or the like, which defines an intermediate horizontal plane of the floor construction and which forms a plurality of ducts for installing or laying of installation components, such as lines and pipes, in the intermediate horizontal plane, and

(ii) a plurality of spacers, which are distributed in the intermediate horizontal plane in at least one zone, termed installation zone, at the side of the trapezoidal metal sheet where said ducts open, and which spacers horizontally between them define spaces in which said installation components are adapted to be laid also in other directions than the direction of the ducts of the trapezoidal metal sheet.

Preferably, all, or at least some of, the spacers in each installation zone are formed in one piece with each other, which facilitates mounting and also ensures that the distance between the spacers will be the desired one. As an alternative, it is possible to imagine that the spacers are formed and mounted as individual units, optionally on a board or the like provided with mounting devices distributed according to a desired pattern of the spacers.

In a preferred embodiment, the construction comprises spacer units to be mounted in the installation zones, each spacer unit comprising on the one hand a metal sheet, board or the like, whose dimension corre- sponds to the entire dimension, or parts thereof, of an installation zone and, on the other hand, a plurality of said spacers which are distributed over and connected with and/or integrated with said metal sheet, board or the like. Said metal sheet, board or the like thus serves as a carrier for a plurality of spacers, which makes mounting quicker and easier. Preferably, the spacer units can be formed in one piece. Each installation zone may comprise one or more such spacer units .

The material of the spacers and any boards or the like for interconnecting the same may be selected to be a material other than sheet metal as long as the necessary loadbearing function is satisfied. In one embodiment of the invention, also a second, lower trapezoidal metal sheet is included, which overlaps the first-mentioned trapezoidal metal sheet and extends into the installation zone. In this case, the spacers may preferably be formed in one piece with the lower trapezoidal metal sheet. In a lightweight module as stated above, such a lower trapezoidal metal sheet may together with the higher trapezoidal metal sheet both be screwed to be floor bars and form a continuous loadbearing floor surface.

The spacers may be formed in one piece with a special metal sheet or the like which is arranged on the lower trapezoidal metal sheet, but it is also conceivable that the spacers are formed in one piece with the lower trapezoidal metal sheet .

The size, number and distribution of the installation zones may vary. A floor construction of a given volume module may comprise a plurality of such installation zones where the installation components can be deflected in any direction, horizontally as well as vertically.

In a preferred embodiment, said trapezoidal metal sheet and said installation zone have essentially the same horizontal extent in a direction perpendicular to the direction of the ducts of the trapezoidal metal sheet. If the floor construction is arranged in a volume module as stated above, it is preferred for each installation zone to extend horizontally to at least one of the four sides of the module . In a preferred embodiment, an installation zone of a first volume module may be located adjacent to an installation zone of an adjoining second volume module, in which case installation components may be extended from ducts in the trapezoidal metal sheet of the first volume module and into the installation zone of the first volume module, so as to change direction in the latter and extend to the installation zone of the adjoining second volume module. In the second installation zone, the installation components may once more change direction and extend into a duct in the trapezoidal metal sheet of the second volume module and/or extend without changing direction through the second installation zone on to the installation zone of an adjoining, third volume module. This laying of installation components can take place in the intermediate horizontal plane, under the superposed panel elements. For instance, the floor construction of a volume module may comprise two installation zones of said type, which are located on opposite sides of the trapezoidal metal sheet and which each have spacers of said type . Furthermore, the floor construction may preferably com- prise such an installation zone adjacent to a wall of a room. In some embodiments, it may also be convenient for the floor construction to comprise such an installation zone located between two trapezoidal metal sheets.

According to a second aspect of the invention, there is provided a modular building, comprising a plurality of vertical frame columns and a plurality of volume modules prefabricated of sheet metal profiles and having a rectangular horizontal section, which volume modules are supported by the columns on one or more floor levels and are provided with floor constructions as defined above. It is preferred for the loadbearing steel bars of the floor construction in a given volume module to consist of sheet metal profiles which form the bottom plane of the volume module. According to a third aspect of the invention, there is provided a method for manufacturing a floor construction, comprising the following steps: arranging a plurality of loadbearing steel bars, preferably sheet metal profiles; arranging a trapezoidal metal sheet or the like on the steel bars, which trapezoidal metal sheet between opposite ends defines a plurality of ducts; arranging a plurality of spacers distributed in a zone, termed installation zone, at one of the opposite ends of the trapezoidal metal sheet; arranging at least one installation component, such as a line or a pipe, so that the installation component extends in one of the ducts of the trapezoidal metal sheet and out into the installation zone between the spacers and there changes direction; and mounting one or more panel elements, such as gypsum boards, on the trapezoidal metal sheet and the spacers in the installation zone.

As mentioned above, the floor construction according to the invention is particularly suited for use in volume modules for manufacturing lightweight buildings. For better understanding of this application of the invention, certain aspects of such volume modules and such buildings will be described below.

Since the modules that are used are preferably made of sheet metal profiles - and, thus, are to be considered "lightweight modules" - it is preferred for the modules to be supported by the columns, so that they are affected in the vertical direction essentially only by their own dead weight and payloads.

The sheet metal profiles from which the volume modules are made and which can also be used for the load- bearing sheet metal bars in the floor construction, preferably have a material thickness of less than 4 mm, preferably in the range 0.5-3 mm. A preferred embodiment is in the order of 2 mm. The volume modules also include, as will be described below, stronger frame edge beams which like the vertical frame columns preferably consist of steel beams, such as rolled steel, with a wall thickness which preferably is greater than 4 mm. The term "volume module" does not relate to a normally closed volume in the first place, but rather a con- structionally and initially open room or framework of sheet metal profiles without side walls, i.e. a module or cassette defined by geometric surfaces (imaginary walls) , referred to as an open system unit. Each "volume module" can be adjusted entirely to the desired form and function of the building and may especially constitute a room of its own or part of a room with adjoining volume modules on the same floor level. Thus, the volume modules can be provided with wall-forming vertical panel elements, at the factory and/or at the building site, according to how the building is divided into rooms.

The volume modules are preferably prefabricated, at least with their sheet metal profiles. Prefabrication usually includes also many other elements, such as board material, infill etc, as will be described below. By "prefabricated" is here meant the state of the module when being positioned in the column frame at the building site. Normally, everything can be prefabricated at the factory, but it is also conceivable that certain parts are mounted later, both before and after positioning the modules in the column frame. Especially a floor construction according to the invention can be prefabricated wholly or partly in such a volume module. The installation components of each module can be installed at the factory to be interconnected at the building site, or alternatively not be installed until at the building site.

An advantage of such volume modules is that they make it possible to stabilise an open, column-supported lightweight structure for taking up the complex of forces that arise in a building. High material efficiency can be achieved by using lightweight construction engineering. It is possible to manufacture a modular lightweight building from prefabricated volume modules, here called lightweight modules. Use of industrially prefabricated lightweight modules has in itself several advantages related to precision, quality, cost and efficiency, such as a small number of mounting operations at the building site and, thus, a short building time.

Description of a Preferred Embodiment The above and other advantages, features and preferred embodiments of a floor construction according to the invention will now be described in more detail with reference to the accompanying drawings, in which Figs 1-30 illustrate a preferred embodiment of lightweight modules and a building made of such modules, and Figs 31 and 32 illustrate an embodiment of a floor construction according to the invention.

Fig. 1 is a perspective view of an embodiment of a volume module formed as a lightweight module. Fig. 1A corresponds to Fig. 1 but shows a lightweight module which is partly open.

Fig. 2 shows an enlarged detail of an upper corner of the lightweight module in Fig. 1.

Fig. 3 shows schematically the roof plane of the lightweight module in Fig. 1 and parts of an adjoining module .

Fig. 4 shows an enlarged detail of the area marked CI in Fig. 3.

Fig. 5 shows schematically the bottom plane of the lightweight module in Fig. 1 and parts of an adjoining module.

Fig. 6 is a schematic side view of a long side of the lightweight module in Fig. 1 and also shows two frame columns . Fig. 7 is a schematic side view of an end wall of the lightweight module in Fig. 1.

Fig. 8 shows an enlarged detail of the area marked C2 in Fig. 7.

Fig. 9 is a broken-away vertical section which shows trapezoidal metal sheets and side bars of two adjoining lightweight modules. Fig. 10 is schematic perspective view of a lightweight module according to Fig. 1 supported by vertical frame columns .

Fig. 11 is a vertical section and shows parts of an embodiment of a building.

Fig. 12 is a schematic top plan view of an embodiment of a building formed as a 6-module system and illustrates neutral zones between the modules .

Fig. 13 is a schematic top plan view of the 6-module system in Fig. 12 and illustrates the principle of horizontal frame stabilisation when subjected to wind loads.

Fig. 14 is a schematic top plan view of a building formed as a double module system and illustrates horizontal frame stabilisation. Fig. 15 is a vertical section according to Fig. 11 supplemented with force arrows that illustrate vertical frame stabilisation.

Fig. 16 is a top plan view of a column portion.

Fig. 17 is a side view of the lower part of a column portion.

Fig. 18 is a bottom plan view of a coupling device.

Fig. 19 is a first side view of the coupling device in Fig. 18.

Fig. 20 is a second side view of the coupling device in Fig. 18.

Figs 21 and 22 show in perspective from above and from below, respectively, two column portions with an intermediate coupling device.

Fig. 23 is a schematic horizontal section of a joint between two modules on the same floor level.

Fig. 24 is a schematic side view - seen towards a frame column - of a joint between two modules on adjoining floor levels.

Fig. 25 is a schematic side view of a joint - seen from a frame column - between two modules on adjoining floor levels. Fig. 26 is a schematic exploded view of a joint between three modules .

Figs 27-30 are schematic perspective views of a joint seen from different directions and with different parts uncovered, to illustrate the construction and function of the joint.

Fig. 31 is a perspective view of an embodiment of a floor construction according to the invention implemented in the floor of a lightweight module. Fig. 32 is a broken-away perspective view on a larger scale of a corner portion of the floor construction in Fig. 31.

Description of a Preferred Embodiment With reference to the accompanying drawings, now follows a description of an embodiment of a modular lightweight building manufactured from lightweight modules and made by a manufacturing method according to the above-mentioned co-pending international patent application. Like components have throughout been given the same reference numerals.

Reference is first made to Figs 1-9, which show a volume module, generally designated 2. The module 2 is intended to be manufactured at a location other than the building site, preferably at a factory so as to make it possible to utilise the advantages of the factory in respect of rational handling of materials, quality and efficiency. At the building site, the volume modules are positioned by means of a crane. At the factory, the volume modules can be customised according to requirements and be provided with the necessary components. Since the entire inner mounting of infill and installation components can also take place at the factory, high- technological and accuracy-requiring operations can take place within the controllable environment of the factory. They can thus be equipped as sanitary modules, dwelling modules etc. The wall faces of the module, i.e. its two long sides 4 and its two short sides or end walls 6, can be opened so that a completed room is made up of one or more modules 2, depending on where wall elements are mounted on the volume modules. Such wall elements can be factory- mounted and/or mounted at the building site.

The volume module 2 is of rectangular horizontal section, which in this embodiment has the dimensions 3.9 m * 7.8 m, including what is below referred to as "neutral zones" NZ between the modules 2 (Figs 12 and 23) . The height of the module is in the shown example 3 m (Fig. 11) .

The volume module 2 is defined by the following geometric planes (see Figs 3 and 5) : two vertical side wall planes 4, two vertical end wall planes 6, a horizontal roof plane 8 and a horizontal bottom plane 10. The vertical planes 4 and 6 can be more or less closed by means of board material, as schematically shown at reference numeral 12 in Fig. 6. The roof plane 8 and the bottom plane 10 of the module 2 are normally closed by panel elements 14 and 16, respectively, of which broken-away parts are shown schematically in Figs 1, 3 and 5 in the form of trapezoidal metal sheet . The volume module 2 is made of sheet metal profiles (beams/girders/bars/panel elements/trapezoidal metal sheets) . The sheet metal profile elements preferably have a material thickness of 1-4 mm, preferably less than 3 mm and most preferred less than or equal to 2 mm. More specifically, the module 2 comprises the following sheet metal profiles :

- two top beams (roof edge profiles) 18 and two bottom beams (bottom edge profiles) 20 which form the longitudinal edges of the roof plane 8 and the floor plane 10; - a plurality of roof bars 22 and floor bars 24 which are extended between and connected with the top beams 18 and the bottom beams 20, respectively; - a plurality of vertical end wall bars 26 along the end wall planes 6 of the module and a plurality of vertical side wall bars 28 along the side wall planes 4 of the volume module (vertical bars can be excluded to some extent) ,

- upper and lower horizontal, side wall bar carrying U profiles 30 (Fig. 9) which extend along and are mounted on the outsides of the top beams 18 and bottom beams 20 and in which the vertical side wall bars 28 are inserted and joined,

- upper and lower horizontal end wall bar carrying U profiles 32 (Fig. 25) in which the vertical end wall bars 28 are inserted and joined, and

- a horizontal U profile 34 (Fig. 25) along the lower edge of each end wall plane 6 for mounting of insulation 36.

The end wall bars 26 and the side wall bars 28 in Fig. 1 can be excluded, when required. The four corner bars and the two central side wall bars 28' (Fig. 1) in each side wall plane 4 cannot, however, be excluded, but are required for transferring of loads. Fig. 1A shows an example of a module 2 where one end wall 6 and one long side 4 have been half-opened for communication with adjoining volume modules (not shown) in the completed building.

Wall boards 12, such as gypsum boards, fibreboards and particle boards, are mounted on the vertical bars 26, 28, as schematically shown in Fig. 6. For instance, six wall boards 12 can be mounted along each module long side 4 in two relatively offset layers. The inner layer is screwed to the vertical side wall bars 28.

The volume module 2 is prefabricated with two frame edge beams 50 which are thicker than the sheet metal profiles. The frame edge beams 50 have several purposes for force transfer, as will be described in more detail below. They are used to transfer forces to adjoining frame edge beams, adjoining frame columns, adjoining modules, adjoining frame-stabilising surfaces and special frame-stabilising systems. A special purpose of the frame edge beam 50 is to form tie beams and compressed beams in connected modules on each floor level . The frame edge beams 50 consist in the shown example of rolled steel beams having a square cross-section of 10 * 10 cm and a material thickness of 5 mm.

The frame edge beams 50 are horizontally extended along a respective upper end wall edge of the module 2 where they are mounted in and carried by the two top beams 18. The frame edge beams 50 and the two top beams 18 are located in a common horizontal plane coinciding with the roof plane 8. This is advantageous both with regard to horizontal force transfer between these com- ponents and with regard to the possibility of extending the room volume of the module 2 in the longitudinal direction of the modules past the frame edge beams 50. More specifically, as best seen on a larger scale in Fig. 2, the top beams 18 formed as C profiles are at their ends provided with vertical openings, which preferably match the outer dimensions of the frame edge beams 50. The frame edge beams 50 extend through these openings and have on the outsides of the top beams 18 free beam ends 52 formed with mounting holes 53 for a coupling device that will be described below.

As best seen in Figs 3, 23-25 and 28, the stronger frame edge beams 50 are attached to the lighter top beams 18 by means of threaded tension rods 54, four for each module. As best seen in Fig. 28, an angular fixing mount 56 for each tension rod 54 is fixedly mounted in the top beam 18. Each tension rod 54 extends through the fixing mount 56, through a hole in the outer roof bar 22 and through a hole in the frame edge beam 50. The tension rods 54 are fixed by means of plates 58 and nuts 60. The tension rods 54 serve to transfer horizontal forces between the frame edge beams 50 and the top beams 18 in the longitudinal direction of the latter. In the first place, the tension rods 54 aim at taking up horizontal forces which strive to displace the frame edge beams 50 away from the module 2 in the longitudinal direction of the top beams 18. As mentioned above, the roof plane 8 and the bottom plane 10 of the module 2 are normally closed by panel elements 14 and 16, respectively, which in the preferred embodiment are made of trapezoidal -profiled sheet metal, which can also advantageously accompany the prefabricated module. The TRP metal sheet is used to transfer horizontal forces to the corners of the module and the frame edge beams 50. It is to be noted that the panel elements 14, 16 also form part of the above-mentioned "sheet metal profiles" of the module and preferably are included in the prefabricated module, especially the bottom metal sheet 16.

Fig. 10 schematically shows how a volume module 2 as described above is suspended from six vertical frame columns 70 (four corner columns and two central columns) , which form part of the loadbearing frame of the building. Each frame column 70 is divided into a number of prefabricated column portions 72, which preferably have such a length that each column 70 comprises a column portion 72 for each floor level. The column portions 72 are preferably steel beams, such as rolled steel. They are dimensioned according to vertical forces and accidental loads. The steel frame is designed so that stabilising forces can be transferred to stabilising units and foundation. As shown in Figs 10, 11 and 16, each column portion

72 is at its lower end prefabricated with a horizontally projecting bottom flange 74 (40 * 30 cm in the shown example) . Each bottom flange 74 is provided with four mounting holes 78, and in the corner columns the bottom flanges 74 are also provided with four upwardly directed stop lugs 76 (Fig. 16) which cooperate with stop lugs 38 in the lower corner portions of the modules 2 (Figs 24 and 32) .

The frame columns ,?0 are torsionally rigidly mounted in the foundation 80 in a suitable manner, for instance by means of plinths 82 according to Fig. 11, which is a schematic side view of a building.

In addition to the frame columns 70, the building can preferably comprise special frame-stabilising elements . Fig. 12, which is a schematic top plan view of a building formed as a 6-module system, shows two such outer frame-stabilising elements in the form of end walls 90 of the building. They can be made of concrete or steel and extend the entire height of the building. Fig. 14, which is a schematic top plan view of a building formed as a double module system, shows schematically five frame-stabilising elements in the form of walls 92 of the building which extend the entire height of the building. In such special frame-stabilising elements, other elements can also be included, such as staircases and/or vertically standing fagade panel elements.

A building according to the embodiment is mounted in the following manner. First the column portions 72 of the first floor level are mounted in a suitable manner in the foundation 80 (Fig. 11) .

Subsequently, the prefabricated modules 2 of the first floor level (including the accompanying frame edge beams 50) are lifted by means of a crane and lowered between the column portions 72 so that each module 2 is made to rest on the bottom flanges 74 of six column portions 72. Once the modules 2 are positioned, a neutral zone NZ (Figs 12 and 23) is present between neighbouring modules 2, which neutral zone in the completed building can be bridged in a convenient manner in roof and/or floor if adjoining modules 2 are to be interconnected. Specifically, the interconnection of the roof elements of the modules can effectively contribute to the stabilisation of the building. The interconnection of the floors of the modules makes it possible to form larger rooms. Once the modules 2 are positioned, the frame edge beams 50 are located in a common plane with the column portions 72, as best seen in Figs 23-25.

It is preferred for the length of the frame edge beams 50 to be such that they extend with their free beam ends 52 into the neutral zone NZ and end at a small distance, suitable with regard to tolerances, from the frame columns 70.

It should be noted that the modules 2 on the first floor level are now supported completely at the bottom, whereas the frame edge beams 50 have not yet been connected with the columns 70.

It should also be noted that the stop lugs 76 of the bottom flanges 74 cooperate with the stop lugs 38 of the modules 2, thereby counteracting horizontal lateral dis- placement of the modules 2.

After having positioned the modules of the first floor level, the frame edge beams 50 are locked to each other and to the column portions 72. In the preferred embodiment, this is carried out by a coupling device 100 (Figs 18-20) separate from the column portions 72, which is used for both interconnections. The coupling device 100 is in the shown embodiment made of three steel sheets welded together: one top sheet 102 and two side sheets 104 with mounting holes 106 and 108/110 respectively. As is evident especially from Figs 23 and 26, such a coupling device 100 is arranged on the column portion 72 where two frame edge beams 50 meet, the top sheet of the coupling device resting on the top of the column portion 72. By means of the two side sheets 104, the beam ends 52 of adjoining modules 2 are connected directly with each other, using bolted joints in the mounting holes 108 and 53. Since the side sheets 104 extend on either side of and immediately adjacent to the column portion 72 (Fig. 23) , the frame edge beams 50 are also locked laterally relative to the frame columns 70. Furthermore the coupling device 100 is locked to the column portion 72 using bolted joints in the mounting holes 110. The frame beams 50 which accompanied the prefabricated lightweight modules 2 are now included as an integrated part of the frame construction of the building and can efficiently transfer forces. Having arranged the modules 2 of the first floor level on the column portions 72, the roof trapezoidal metal sheets 14 of adjoining modules 2 are interconnected by means of separate panel elements in the form of trapezoidal metal sheets 15 rotated through 90 degrees (Fig. 23) . Thus a larger continuous frame-stabilising surface is formed on the floor level .

Subsequent floor levels are then mounted in the same way. In the frame columns 70 where coupling devices 100 are included, the column portions 72 on the second floor level will be arranged with their bottom flanges 74 on top of the coupling device 100 and connected by bolted joints through the mounting holes 78 and 106. As an alternative, the coupling device 100 can be integrated into the column portions 72.

Different Module Systems

A module 2 according to the shown embodiment usually has a floor surface of about 27 m², or more if extended. By consolidating two or more modules, they may be adjusted to optional layouts, as mentioned above and as indicated in Fig. 1A. The modules are delivered with or without side walls but are otherwise usually identical. The bottom flanges 74 of the corner columns 70 are loaded with one to four modules according to the selected lay- out. The bottom flanges 74 of the central columns 70 are loaded with one or two modules according to the selected layout . According to the selected layout, stabilisation may be accomplished in four different ways:

Single module system Double module system Multi module system 6-module system

Single Module System Singe module system means that each module 2 takes its own stabilising force and conducts this vertically down to the foundation 80 through subjacent modules 2. The boards 12 in all four boundary walls 4, 6 are used as frame-stabilising surfaces. Fig. 15, which corresponds to the vertical section in Fig. 11, shows schematically by means of force arrows how a horizontal wind force F acting on the second floor level is taken up by the building and transferred directly vertically to the foundation. This is in contrast to other embodiments where the force can be transferred between horizontally adjoining modules. This makes it possible to eliminate outer stabilising fagade elements, such as concrete walls.

The wind force F is transferred through the end wall of the module to the floor and roof board 14, 16. Adjacent to the floor board 16, the force is then transferred to the longitudinal bottom beams 20 of this module 2. Adjacent to the roof board 14, the force is transferred through vertical wall elements 12 down to the bottom beams 20.

Thus a horizontal compressive force F4 arises in the right joint, as indicated in Fig. 15. This horizontal compressive force F4 is transferred through the stop lugs 38, 50 to the column flange 74 and through the coupling device 100 down to the frame edge beam 50 of the subjacent module 2. The force F4 is now taken up in the top beam 18 of the subjacent module 2 through two tension rods 54 which are connected to the beam 50 precisely to take up such horizontal forces. A tensile force F5 thus arises in the right joint and also in the left joint in Fig. 15. In the left joint in Fig. 15, the force is now once again taken up by the vertical panel element 12 of the module, as indicated by the force arrow F6. Finally the wind force is transferred to the foundation 82.

Double Module System

Double module system (Fig. 14) means that each module 2 takes its own stabilising force in the same way as the single system, except that an apartment-separating partition wall 92 is missing. A double room volume is obtained. The systems of joists between the modules 2 are connected so that the board effect in the systems of joists can be utilised. The system can be combined with a stabilising steel frame.

In a double module system, only plinths 82 under the transverse walls 92 are affected by stabilising forces. A double module system can be supplemented with a stabilising steel frame arranged in the partition wall at a distance of maximum 4 modules. In this case, higher buildings can be erected.

Multi Module System

Multi module system means that the modules 2 are provided with an outer stabilising wall 90 arranged between each module. The wall is best made of concrete cast in situ in the form of semiprefabricated parts, width of the wall about 0.5 m.

Stabilising forces are transferred through the roof boards 14 interconnected by means of the metal sheets 15 - said roof boards jointly forming a frame-stabilising surface in the roof plane 6 for each floor level - to outer stabilising constructions and do not affect the plinth foundation 82. 6-Module System

6-module system (Figs 12 and 13) means that the systems of roof joists between the modules 2 are connected with the metal sheets 15, thereby making it possible to use the board effect.

The stabilising walls 90 or staircases are made of steel or concrete in the traditional way.

Stabilising forces are transferred through the roof boards 14 interconnected by means of the metal sheets 15 - said roof boards jointly forming a frame-stabilising surface in the roof plane 6 for each floor level - to outer stabilising constructions and do not affect the plinth foundation 82. Thus, horizontal stability is achieved by the interconnected roof boards and trans- ferred to the end walls 90 of the building by means of the interconnected frame edge beams 50. This is contrary to the single module system where the horizontal stability is achieved through the board effect in the vertical (gypsum board) walls 12. In Figs 13 and 14, force arrows indicate schematically how a horizontal (distributed) wind load F coming sideways is taken up in the floor boards 14, 15 and is transferred to the mutually linearly interconnected frame edge beams 50 on each floor level as tensile forces FI and compressive forces F2 , respectively, which are transferred horizontally to the end wall elements 90/92 which transfer the force F3 down to the foundation 80.

The interconnected frame edge beams also act to keep the building together.

Floor Construction

Reference is now made to Figs 31 and 32 which illustrate a preferred example of a floor construction according to the invention, provided with installation zones and implemented in a lightweight module as described above. Fig. 25 also shows parts of the floor construction. As shown in Fig. 31, the floor trapezoidal metal sheet 16 of the lightweight module 2 is divided into two trapezoidal metal sheets 16-1/16-2, whose length and position are such that (i) the trapezoidal metal sheets 16-1/16-2 terminate at a distance from the opposite end walls of the module 2 to form two end wall installation zones IZ-1, and (ii) the trapezoidal metal sheets 16-1/16-2 are spaced apart to form a central installation zone IZ-2. In the shown example, each installation zone accommodates a lower trapezoidal metal sheet 130 which partly overlaps the higher trapezoidal metal sheet 16. Thus, in the example the lower trapezoidal metal sheet 130 has no direct contact with the superposed board material 17, such as gypsum boards (Fig. 25) . The two trapezoidal metal sheets 16 and 130 are suitably anchored by means of screws in the floor bars 24 and the lateral floor profiles 20.

Each installation zone IZ-l/lZ-2 further contains a plurality of spacers 132 which are distributed in a suitable manner in the installation zone. The purpose of the spacers 132 is to support that part of the board material 17 which extends into the installation zone and thus is not supported by the ridges of the trapezoidal metal sheet 16. A further purpose of the spacers 132 is to define between them spaces or interspaces in which installation components, such as lines and pipes, may be installed in a suitable direction.

The number, cross-section, relative distance, dis- tributional pattern etc. of the spacers may be adjusted in a suitable manner according to loads that are to be taken up, dimension of installation components, number thereof etc. However, it should be noted that such a plurality of spacers that are spaced from each other give a high degree of flexibility for the laying of installation components . The installation work may largely be made at the factory when manufacturing the prefabricated module, and be terminated at the building site.

The spacers may also serve as deflection points, as will be shown below. In the embodiment illustrated, the spacers 132 are in each installation zone supported by a metal sheet or plate 131 to form a building component that can be mounted as a unit in the installation zone. For larger installation zones, several such units may be used together. Such a unit may be pressed or formed in one piece of a suitable material, such as thin metal sheet material, but can alternatively also be made from separate parts.

As shown in Fig. 32, an installation component, such as a line 138, may be laid in one of the upwardly open ducts 133 of the trapezoidal metal sheet 16 and, at the opening of the duct 133, be extended into the installation zone IZ-1 and there be deflected about one of the spacers 132 to extend in another direction, as shown at 139. It is also conceivable to arrange installation com- ponents in the downwardly open ducts of the trapezoidal metal sheet, or in both upper and lower ducts.

The line 138 can, for instance, be installed (i) horizontally to an adjoining installation zone on the same floor level, (ii) horizontally in a U-shaped path to a parallel duct in the same trapezoidal metal sheet 16, (iii) vertically upwards to a wall of a room to be connected to, for instance, a radiator, a wall socket etc, or (iv) vertically upwards or downwards to an adjoining floor level. After arranging the line 138, the board material 17 is mounted, as shown in Fig. 25. As an alternative, the line can be inserted into the duct after mounting of the board material 17.

If two modules 2 are to be interconnected to form a larger room, it is possible to arrange in the neutral zone between the modules an intermediate trapezoidal metal sheet 19, as illustrated in Fig. 31, which also supports the board material 17. If this intermediate trapezoidal metal sheet 19 is arranged at an angle of 90 degrees according to Fig. 31, lines/pipes 138 from the installation zones IZ-1 and IZ-2 may unimpededly be extended between the installation zones of neighbour- ing modules through the ducts of the trapezoidal metal sheet 19.

The floor construction according to the invention affords complete flexibility for installing lines and pipes and yet rational manufacture of the floor of the lightweight module, with its 2 -zone composition of longitudinal zones and deflecting zones.

Finally, it should be particularly noted that since horizontal stabilisation can be achieved outside the floor, as described above in conjunction with intercon- nection of floor panel elements, such an installation floor can be arranged without having an adverse effect on stabilisation.

Claims

1. A floor construction, comprising a plurality of loadbearing steel bars (24) , preferably sheet metal profiles, and one or more superposed panel elements (17) , such as gypsum boards, c h a r a c t e r i s e d in that the panel elements (17) are supported by the steel bars (24) via: (i) at least one trapezoidal metal sheet (16) or the like, which defines an intermediate horizontal plane of the floor construction and which forms a plurality of ducts (133) for laying of installation components (138) , such as lines and pipes, in the intermediate horizontal plane, and

(ii) a plurality of spacers (132) which are distributed in the intermediate horizontal plane in at least one zone (IZ-1; IZ-2), termed installation zone, at the side of the trapezoidal metal sheet (16) where said ducts (133) open, and which spacers (138) horizontally between them define spaces in which said installation components

(138) are adapted to be laid also in other directions

(139) than the direction of the ducts (133) of the trapezoidal metal sheet (16) .

2. A floor construction as claimed in claim 1, wherein all, or at least some of, the spacers (132) in each installation zone are formed in one piece with each other.

3. A floor construction as claimed in claim 1 or 2, comprising spacer units to be mounted in the installation zones, each spacer unit comprising on the one hand a metal sheet, board or the like (131) , whose dimension corresponds to the entire dimension, or parts thereof, of an installation zone (IZ-1; IZ-2) and, on the other hand, a plurality of said spacers (132) which are distri- buted over and connected with and/or integrated with said metal sheet, board or the like.

4. A floor construction as claimed in any one of the preceding claims, further comprising a second, lower trapezoidal metal sheet (130) which overlaps the first-mentioned trapezoidal metal sheet (16) and which extends into the installation zone (IZ-1; IZ-2) .

5. A floor construction as claimed in claim 4, wherein the spacers (132) are formed in one piece with the lower trapezoidal metal sheet (130) .

6. A floor construction as claimed in any one of the preceding claims, wherein the floor construction comprises two installation zones (IZ-1; IZ-2) of said type, which are located on opposite sides of the trapezoidal metal sheet (16) and which each have spacers (132) of said type .

7. A floor construction as claimed in any one of the preceding claims, wherein the floor construction comprises such an installation zone (IZ-1) adjacent to a wall of a room.

8. A floor construction as claimed in any one of the preceding claims, wherein the floor construction comprises such an installation zone (IZ-2) located between two trapezoidal metal sheets (16) .

9. A floor construction as claimed in any one of the preceding claims, wherein said trapezoidal metal sheet (16) and said installation zone (IZ-1) have essentially the same horizontal extent in a direction perpendicular to the direction of the ducts of the trapezoidal metal sheet (16) .

10. A modular building, comprising a plurality of vertical frame columns (70) and a plurality of volume modules (2) prefabricated of sheet metal profiles (18-32) and being of rectangular horizontal section, which volume modules are supported by the columns (70) on one or more floor levels and which are provided with floor constructions as claimed in any one of claims 1-8.

11. A method for manufacturing a floor construction, comprising the following steps: arranging a plurality of loadbearing steel bars (24) , preferably sheet metal profiles; arranging a trapezoidal metal sheet (16) or the like on the steel bars (24) , which trapezoidal metal sheet (16) between opposite ends defines a plurality of ducts (133) ; arranging a plurality of spacers (132) distributed in a zone (IZ-1; IZ-2), termed installation zone, at one of the opposite ends of the trapezoidal metal sheet (16) ; arranging at least one installation component (138) , such as a line or a pipe, so that the installation component extends in one of the ducts of the trapezoidal metal sheet (16) and out into the installation zone (IZ-1; IZ-2) between the spacers (132) and there changes direc- tion (139) ; and mounting one or more panel elements (17) , such as gypsum boards, on the trapezoidal metal sheet (16) and the spacers (132) in the installation zone (IZ-1; IZ-2) .

12. A method as claimed in claim 11, wherein the step of arranging a plurality of spacers (132) comprises the step of arranging in the installation zone (IZ-1; IZ-2) a metal sheet, board or the like (131) provided with said plurality of spacers (132) .