WO2005093185A1

WO2005093185A1 - Modular building system

Info

Publication number: WO2005093185A1
Application number: PCT/GB2005/001191
Authority: WO
Inventors: Barry Urquhart
Original assignee: Barry Urquhart
Priority date: 2004-03-24
Filing date: 2005-03-24
Publication date: 2005-10-06
Also published as: EP1740787A1

Abstract

A set of panels forms a modular building system, the set comprising a wall unit, a window unit, and a door unit. Each panel comprises a wooden framework with a skin on at least one side. A wall unit, a window unit with a wide window, a window unit with a narrow window, and a plain wall unit, are all of the same width, plus a plain wall unit of smaller width. The panels may be assembled from sub-panels. The panels are combined to form a building, preferably multi-storey, comprising a plurality of units, and the buildings can be combined to form a development.

Description

Modular Building System

The present invention relates to modular building systems, and particularly to such systems intended for low cost ("affordable") housing.

There is a need for low cost or so-called affordable housing. In cities in particular, such housing is generally of high density, since the cost of land is high. Since costs are high while the housing is intended to be cheap, such housing often tends to be generally functional but unattractive.

In increasing order of detail, the present invention is concerned with a concept for a building system, the layout and juxtaposition of the units of the system, the units or modules of the system, the use of wood panels and wood corner and end posts therefor for the units, and the manner in which the panels are connected to the posts by means of male and female joints.

Various plans of developments in accordance with the present invention and details of the modules and panels thereof will now be described by way of example and with reference to the drawings, in which: Figs. 1-1 to 1 -4 are plans of typical layouts for the present housing developments; Figs. 2-1 to 2-3 are ground, first, and second floor plans of a part of the development of Fig. 1-1; Figs. 2-4 and 2-5 show floor plans of part of a development similar to that of Fig. 1 ; Fig. 2-3 A is an alternative second floor plan to Fig. 2-3; Fig. 3 shows an elevation of the layout of Figs. 2-1 to 2-3; Figs. 4-1 to 4-3 show a set of panel designs; Figs. 4-4 and 4-5 show a further preferred set of panel designs, ? Fig. 4-6 shows a further preferred set of panels; Figs. 5-1 , 5-2A, and 5-2B show the panel joining technique; Figs. 5-3 and 5-4 show developments of the panel joining technique; Figs. 5-6 to 5-8 show further aspects of the panels and their joining; Fig. 6 shows a layout for a 5 person 3 bedroom unit, single staircase (in this and in Figs. 7, 9, and 10, the doors to the stair/lift lobby open out on the ground floor); Fig. 7 shows a layout for 4 a person 2 bedroom unit, single staircase; Fig. 8 shows a layout for a 3 person 2 bedroom unit, single staircase; Figs. 9 and 9A show ground and first floor, 4 person 2 bedroom units, with a single staircase (the windows 60 being optional); and Fig. 10 shows a combination of different 6m units.

The present system is based on a standard module, which can conveniently be a 6 m square module. A single module can be used as a housing unit; however, 2 (or more) modules can be combined, vertically or horizontally (or both) lo form a larger housing unit.

Fig. 1 -1 shows a typical layout using the present system. This is formed of square blocks 10 and linear blocks 12. Each square block 10 consists in plan of four modules arranged in a square; each linear block 12 consists in plan of a line of modules (in this case, 4 modules). As explained in more detail below, a unit may consist of more than one floor (vertically stacked modules), and/or there may^¬ be 2 or more units arranged vertically above each other. In plan, every unit with a ground level module has its own small garden area - areas 1 1 for blocks 10 and areas 13 for blocks 12.

The layout is organized into regions or superblocks 17, each region consisting of four blocks 10 and two blocks 12 arranged around a central square 14. The square 14 will typically be grassed and with trees or bushes, with paths 15 running in a convenient pattern through it. Parking areas 16 are arranged adiacent to the regions.

Fig. 1 -2 shows an alternative layout of more linear form. This has a cen- tral road 21 running through it, so that a region 20 is formed by a pair of blocks 10 and a block 12. (The blocks 12 are shared between adjacent regions ) A region

20 has a central common "square" or area 21 . To some extent, a pair of regions

20 facing each other across the road 21 will form a single combined region Fig. 1 -3 shows a further possible layout, similar to the Fig. 1 -2 layout but of less linear form

Obviously the arrangement of the modules and units in the blocks and of the blocks in the layout can both be varied widely. Thus, for example, as shown in Fig. 1 -4, the positions of the gardens can be varied; the numbers of modules along the linear blocks can be varied, with different linear blocks having different lengths; and with a layout having a linear portion like that shown in Fig 1 -2. the square blocks may be positioned opposite linear blocks. And at an extreme, a module can stand alone, or be combined horizontally with just 1 other module

Fig. 2-1 shows the ground floor level of half of a region 14 of the Fig. 1 -1 layout in more detail. Each block 10 consists of four modules 25; each block 12 consists of four modules 26. The modules 25 are all identical, as are the modules 26. The internal layouts can however differ widely, eg to provide 4 person. 3 bedroom or 3 person. 2 bedroom units, and different internal layouts can be mixed freely in the various blocks, both horizontally and vertically.

The design of the accommodation is such as to give pleasantly proportioned rooms, with many of the principal rooms being double aspect (windows on two sides). Fig. 2-2 shows the first floor level corresponding to Fig. 2- 1. The units 25 are 3-bedroom units; the units 26 are 2-bedroom units.

Fig. 2-3 shows the second floor level corresponding to Figs 2-1 and 2-2 Block 10 has two double-module flats 28; each of these is bounded by a panel at each end and two panels along each side. Block 10' also has two. double-module flats 31 and 32, with flat 32 being larger than two modules and flat 32 being smaller than 2 modules. These units 31 and 32 are however still bounded by the same types of panel, with the dividing panels being shifted in position from the midway line. Block 12 has 4 units 29, similar to the units 26. Block 12 also has a third floor level (not shown) similar to the first floor level of that block.

A walkway 30 is provided to give access to the units of the second floor level. A stairs and lift module 27 provides access to the walkway from ground level.

Fig. 3 shows an elevation of the layout of Figs. 2-1 to 2-3. (The elevation will of course depend on the numbers of modules and units and how many modules are stacked vertically in the various blocks.)

Fig. 2-4shows a layout for a group of flats intended for combinations less than 4 storeys high. This shows a group of 6 flats around a central area containing stairs and a lift. It will be noted that each group of 3 flats has a common access region which forms part of the central area but is demarcated by a pair of doors, so enhancing privacy. Similarly, the central area lies on an extended corridor giving communication with adjacent groups of flats, but is demarcated by- pairs of doors.

Fig. 2-5 shows a further layout for a pair of adjacent flats fronting onto a walkway. Turning now to the details of the design and construction of the units, the design is based on a single module of standard size, preferably 6 m square (though, as described for units 31 and 32, adjacent modules can be of different sizes provided that the excess of one matches the deficit of the other).

The units are bounded by panels of a minimal number of different types. In the layouts described above, there are only 3 panel types required; a blank panel 29 dividing each unit from the adjacent units, a door and window panel 28 having two openings at predetermined positions, and a two window panel 33 having two openings at predetermined positions. (As will be explained below, there are two face-to-face panels dividing adjacent modules.) Fig. 4-1 shows the designs of these 3 panels (panel 28 can of course be turned round if a right-hand door is required). If desired, however, a few further types of panel may also be used, such as panels 34 and 35 (Fig. 4-2) for 4-person 2-bedroom flats and panels 34 and 36 for 4-person 2-bedroom and 3-person 2-bedroom flats (typically provided on upper floors). Fig. 2-5 shows a modified form of the top left-hand panel of Fig. 4- 1, in which the window is smaller and higher, giving greater privacy.

Fig. 4-4 shows a second and preferred set of panels. The first three are external panels; the fourth is an internal separating wall panel; these are all 3000 mm wide (the heights are obviously all equal, but the actual height is not critical).

The final three are subsidiary or auxiliary panels which are not essential, but are useful for certain unit designs (4-person 2-bedroom flats). Fig. 4-5 shows the structure of the first panel. As shown, it consists of a wooden frame with vertical internal elements at 600 mm spacing, covered with plywood or the like. The regular spacing of the internal elements is broken where the opening (here, a doorway) is located. The outer vertical elements have extra strength, achieved here by doubling them; similar strengthening is provided around the opening. The construction of window panels is analogous. Fig. 4-6 shows a further set of panels, which are in effect sub-units of the panels just discussed and can be combined to form door, window, and solid panels. The dimensions of most of these sub-unit panels are multiples of 500 mm, and these form a set which permits s wide variety of unit constructions An additional 1200 mm panel may also be included, giving still greater flexibility of unit construction. These panels may be used where handling the full-sized panels is inconvenient.

The panels can be provided in open or closed form, ie with a skin on one or both sides. In the closed form, insulation will be included in the panel; in the open form, insulation will normally be added during construction of the building, when the second skin will be added.

Each unit is constructed of a timber frame of vertical posts with panels between them. The panels are wood frame panels, comprising wooden struts along their edges and defining any door and window openings, plus and internal struts required for strength in large unbroken areas. The panels have plyw ood facings, and internal heat and sound insulating material. The floors dividing stacked modules are also wooden, 6 m square. Any outside surface for the panels is possible, with the use of breather paper and battens and/or cross battens to take timber, brick (brick slips), and waterproof cladding. The design encourages flexibility of materials and expression of colour.

The division between two adjacent modules is formed by a pair of face-to- face solid panels. This forms a high quality solid party wall between the modules

Each unit can be prefabricated and sent to site as either house or flat or maisonette modules; alternatively, the panels can be sent to the site individually as assembled into modules on site. Internal divisions (walls) within units are typi- cally stud walls of wooden studding covered with plasterboard. This allows great freedom in designing the internal layout within modules. Fig. 5-1 shows the technique for joining panels are a corner. Two panels 40 are joined to a corner post 50. One panel 40 has a strut 41 forming one edge, with a pair of struts 42 projecting from it with a spacer 43 between them. The 5 corner post 50 has a projecting tongue 51 , supported by support elements 52. The tongue 51 forms a male element received between the two struts 42 which together form a female groove element. The joint is secured by bolts 45. The elements 44 and 53 are battens for fixing external wall coverings. 0 Fig. 5-2 A shows a joint including a centre post, which in this case is formed by two adjacent pillars 50'. The two outer panels 40 are joined to the post in a way generally similar to that of the Fig. 5-1 fixing. The two internal panels 40' (forming the double thickness wall mentioned above) are joined to the centre post by simple butt joins. Fig. 5-2B shows a variant of this arrangement using a single

15 pillar or column 50". Spacer elements 45 are inserted as appropriate.

Figs. 5-3 and 5-4 show minor variations on this construction. In Fig. 5-3, 70 is a strut added and bolted to both panels at the corner; 71 is a ply infill piece at the junction of two panels. In Fig. 5-4, 72 shows two layers of gypsum based 20 board, as an additional lining is required where kitchen units back onto a separating wall. 73 in an external skin or cladding (shown as timber); 74 is a vapour control membrane; 75 is a cavity barrier; 76 is a batten for carrying the external cladding; and 77 is a 12.5 mm gypsum board where there is no separating floor (2 layers if there is a separating floor).

23 Fig. 5-5 shows a cut-out 80 for services in a panel, and also pins 81 for joining panels stacked vertically; Fig. 5-6 shows a panel with tongues 82 for the same purpose. Fig. 5-7 shows panels linked vertically by pins 81 and tongues and grooves 82, together with vertical end fixings 83. (In practice, pins and tongues

J o will not normally be mixed in a single constαiction.) If desired, the floor panels can be positioned between successive wall panels, with each wall panel l inked to the two wall panels above and below it by pins or tongue and groove elements

All services are either incorporated in the house module per floor, or in the panel system if prefabricated. Water services are preferably confined to 1 or at most 2 panels per module.

Fig. 1 1 shows three different size units (3 person 2 bed, 4 person 2 bed, and 5 person 3 bed), using 3m spans with 1.5m make-up pieces.

Fig. 12 shows the panel construction for a corner junction, separating wall, and a panel junction in the same unit. These constructions use 140 x 50 mm timber posts; for lower buildings, 89 x 50 mm posts can be used in a similar manner.

Fig. 13 shows a layout of 4 and 5 person units, multi-storey, with escape routes. This layout can be extended as required. Fig. 14 shows a variation on the preceding square. Fig. 15 shows a further layout variant. The lower central open area can be formal or informal, with lawn, planting, seating, and pedestrian access for quiet seclusion. The upper outer open areas are for playspace for ball games- etc Fig. 16 shows a house/maisonette plan, front & side aspect. Door 61 is a house access door or a wall for maisonette; door 62 is the main entrance door for the house or maisonette. Fig. 17 is a layout for a combination of units Fig 1 8 shows a house/maisonette plan, front & rear aspect. The main entrance door is 63 for both the house and the maisonette. Fig. 19 shows a typical elevation of a square with houses and maisonettes on the ground and first floors and flats and maisonattes oin the second and third floors. The blocks can be interchanged to give one to four stores; flats can be in any combination to six or seven stories. Fig. 20 shows another typical elevation of a combination of units. A square is shown with houses and/or maisonettes on the ground and first floors ands flats on the third floor. The houses with a front and rear aspect have maisonettes on the second and third floors.

One preferred arrangement is for the ground and first floors to have either houses or maisonettes, and for the second floor to have either flats at that level or maisonettes on the second and third floors. This gives a varying height roof elevation. However, the blocks of flats can go to six or seven stories.

In its preferred forms, the present invention thus provides a housing system which promotes social interaction and cohesion and is reasonably attractive in appearance (including being relatively low rise), while being relatively cheap and high density.

In the claims, all references in parentheses to technical features are references within the meaning of EPC Rule 29(76), whether the reference are lo individual features within specific figures or to complete figures, and are not to be taken as implying reliance on those features within the meaning of Rule 29(6).

Claims

1 A set of panels forming a modular building system, the set comprising a wall unit, a window unit, and a door unit (Figs. 4-1 to 4-3).

2 A set of panels according to claim I wherein each panel comprises a wooden framework with a skin on at least one side (Fig. 4-5).

3 A set of panels according to either previous claim comprising a wall unit, a window unit with a wide window, a window unit with a narrow window', and a plain wall unit, all of the same width (Fig. 4-4).

4 A set of panels according to claim 3 further including a plain wall unit of smaller width (Fig. 4-5).

5 A set of panels (Fig. 4-6) assemblable to form the panels of any previous claim.

6 A building constructed from the panels of any previous claim.

7 A multi-storey building according to claim 6.

8 A multi-storey building according to claim 7 wherein each storey includes a plurality of units.

9 A building according to claim 7 wherein the panels are joined vertically by pins or tongue and groove elements (Figs. 5-5 to 5-7). 10 A building according to any of claims 6 to 9 wherein the panels are attached to wooden pillars.

1 1 A building according to claim 1 1 including cladding on the outside of the panels.

12 A building development comprising a plurality of buildings according to any of claims 6 to 11.

13 A set of panels forming a modular building system substantially as herein described.

14 A unit substantially as herein described.

15 A building substantially as herein described.

16 A development comprising a set of buildings substantially as herein described. 17 Any feature of novelty or combination thereof within the meaning of Article 4H of the International Convention (Paris Convention).