WO2009105050A1

WO2009105050A1 - Transportable modular building system produced and constructed at the factory and the method for the production of the module thereof

Info

Publication number: WO2009105050A1
Application number: PCT/TR2009/000030
Authority: WO
Inventors: Mustafa Sak
Original assignee: Mustafa Sak
Priority date: 2008-02-22
Filing date: 2009-02-20
Publication date: 2009-08-27
Also published as: TR200801175A2

Abstract

The invention relates to a modular building system, which involves the production of the modules (30) obtained by joining, on a carcass structure (10) that constitutes the main body and according to the desired architectural features, the panels formed according to certain standards in an environment different than the construction zones, preferably in a factory environment (51), and the delivery of said modules (30) by transport means (53) to a site (54) requested by the customers and the combination of more than one module (30) based on the desired m² and the placement of the same in a way to suit the different types of houses as demanded by the customer.

Description

TRANSPORTABLE MODULAR BUILDING SYSTEM PRODUCED AND CONSTRUCTED AT THE FACTORY AND THE METHOD FOR THE PRODUCTION OF THE MODULE THEREOF

Technical Field

The invention relates to a modular building system, which involves the production of the modules obtained by joining, on a carcass structure that constitutes the main body and according to the desired architectural features, the panels formed according to certain standards in an environment different than the construction zones, preferably in a factory environment, and the delivery of said modules by transport means to a site requested by the customers and the combination of more than one module based on the desired m² and the placement of the same in a way to suit the different types of houses as demanded by the customer.

The invention also encompasses, in addition to the structural and production-related details of the panels that constitute the modules, the formation of the finished building by said modules and the placement of the same on an area demanded by the customer.

State of the Art

The increased need in the market towards the residences, parallel to the increasing population in particular, leads to the questioning of the practice that involves the preparation of the buildings in the form of on-site constructions. A considerable extent of labor, equipment and hardware are required for every building that is constructed on- site. Delivery of the equipment and the necessary hardware to the construction site necessitates an extra cost. In addition, a wide area is required, which is referred to as a construction site. Spreading of said equipment and the worker's comfortable behavior on this site to stack and haul to the construction the hardware required for the building cause an increase in the area needed besides the construction itself. Furthermore, the hauling of said construction materials to this area and the fact that the construction workers work for certain time periods at different zones in each construction lead to an increase in the required time and costs.

In order to solve the said technical problem, the present invention proposes to form the carcass structure, which will be produced in a factory environment and delivered by various transport means to the construction site in the form of ready to use modules and will constitute the main body of the finished building, to produce and keep in stock in certain quantities the panels or the building components which have been previously prepared according to certain standards, to prepare, at the factory, by combining said panels on the carcass structure in a manner to suit the desired architectural features, within a short time upon the receipt of an order the modules, and to deliver the formed modules to the construction site and to position the same at their location within a brief span of time. It is possible to combine several of said modules according to the need, as well as it being possible for a single module to comprise the finished building in cases where residences with a small number of m^2ls are needed.

Also, according to another solution put forward by said invention, it is aimed to produce said modules by an alternative method and to improve the strength owing to this method. Following the formation of the carcass structure according to the alternative production method disclosed herein, it is enabled to complete the module production by laying out the necessary installations (bathroom/wc sewerage, electricity, fresh water), casting concrete onto the side (curtain), top and bottom surfaces of the carcass structure by the use of the moulds, and after the process of concrete casting, performing the we, kitchen, bathroom arrangements and the wall tile and plasterboard works within the module so that the concrete may be dried to be brought into a ready to use position and finishing the painting procedures for the exterior surface -it being also possible to use other exterior surface applications.

According to the state of the art, one encounters the patent applications related to the transportable residence systems. However, said applications are far from constituting a solution for the problems which have been present in the art for a long time. For example, in the European patent no. EP 0717158, a system associated for the structural zones are described for the purpose of the erection of the buildings. In said patent, the room modules are described, which are formed with the same height from reinforced concrete or similar structures, according to said system. Said modules constitute the rooms and these comprise rectangular room cells having at least three side walls and a floor plate and also a ceiling.

The US patent no. US 4,050,215 solves the problem of flexibility and excessive material use resulting from the use of the floor and the walls twice (doubling) in the modular structures. Said modules are comprised by at least two parallel vertical walls and a floor surface, and there is no ceiling surface in the lower modules, other than the modules to be located in an upper section.

Further, in the US patent no. US 4,275,533, a transportable building and a method for carrying the same are proposed. Here, a transportable building is described, to which the ceiling, floor and the side walls are structurally connected in order to form an integrated building unit. The building includes the sliding means to enable the building to hold onto the earth and to support the building in a free standing position, and the sliding means formed immediately beneath the building floor in order to attach the same to the vehicle's chassis members and to support the same, such that the building can withstand the sliding stresses during the sliding of the building upon the vehicle for the purpose of loading and unloading. Said modular building application offers solution only to the requests of buildings with small number of m² and with said application, it is not possible to form a building embodiment with desired width and architectural features by way of combining and joining several modules.

In the US patent no. US 5,906,075, another modular building structure is disclosed. The prefabricated, transportable and reusable semi-continuous modular building embodiment is provided for being appended to the common corridor of a continuous building, in order to increase the size of the same. In order to define the continuous framework of the building, it is established on a plurality of the foundation units arranged along the earth. At least one building unit is placed on the foundation units.

In a further US patent no. US 6,067,771 , the apparatus and method for the production of the modular building are disclosed. In this patent, it is proposed to construct a modular building in a module production zone by way of combining the previously made components manufactured in a production zone. The previously prepared component parts are measured, cut and delivered to the equipment production area and are provided to a module constructor in a module construction area. The module constructor combines the modules without measuring, cutting or perforating the component parts. The building embodiment put forward in said patent bears risk with regards the strength and no information is provided in the patent concerning the layout of the installations essential for the user, particularly electricity and water. As a result, a modular building structure is put forward, which may be used only as a temporary residence and lacks the hardware required for the use thereof as a permanent residence.

In the PCT application with the publication no; WO 2005/088021 , a transportable modular building and a method for constructing the same are described. Here, a modular building embodiment is described, which is of the type capable of being moved within a container in a factory environment and being assembled in the same manner, e.g. the factory production of at least one service module that allows the container transportation and is equipped with appropriate building installation systems. The mention is made in said patent of a module embodiment produced in a way to permit the container transportation, but it is contemplated to expand the building by the additional vertical and horizontal parts which are also transported within the container. For this reason, the practice remains far from an approach of modularity wherein the production is performed completely at the factory and only the combination procedure is carried out at the construction zones, with the result that extra labor and cost emerge.

In a further PCT application with the publication no; WO 2005/093181 , a modular container is described, which may be converted into a prefabricated building. Here the components and the structural transformations are described, which are used for the transformation of a container, having standard dimensions and structural members, into a building.

When the patent applications exemplified above, the prior art documents and the applications employed in the state of the art are examined, no study is encountered concerning a modular building system, wherein all the production procedures are completed in a factory environment for the models that emerge as a result of the combination, on a carcass structure constituting the main body and according to the desired architectural properties, of the panels which have been previously determined and kept in stock during the course of serial production and said modules are delivered by transport means to a site requested by the customer and more than one modules are easily combined and positioned according to the desired m².

Brief Description of the Invention

The invention which is tried to be described herewith relates to a module production method, which satisfies the requirements that are not described in the aforementioned prior art and exist in the current state, eliminates all the disadvantages and brings about some additional advantages, and also to a transportable modular building system associated with the conveyance of the produced modules to the construction site.

The object of the invention is to enable the placement, within a short time, of the building for which the order is placed by a customer via catalog and/or the internet, on the area requested by the customer, and the supply of the same to the use in a manner to satisfy all the needs of the customer.

The object of the invention is to enable all the procedures for the modules to be completed within a factory through a process of automation, by way of combining the previously prepared parts, just like the case applicable to an automobile factory.

The object of the invention is, contrary to the on-site methods of construction and the existing buildings, to put forward a modular building, which is realized according to the desired architectural features by combining, in a factory environment and on a carcass structure formed from steel material, the panels previously determined and able to be kept in stock through a process of serial production, and which is, upon the receipt of a demand, transported within a very short time period to a previously prepared desired site and is combined.

The object of the invention is to put forward a building embodiment, which is completely ready for use upon the placement of all the installations (electricity, water, sewerage, heating, cooling, etc.) required by the user into the panels constituting the modules, and upon the combination of said modules at the desired site.

Another object of the invention is to put forward a building embodiment, which is improved both in strength and isolation, owing to the panels placed on the carcass structure being provided with the isolation and filling materials in possession of the desired technical characteristics. As such, said building embodiment is distinguished from the prefabricated buildings.

Another object of the invention is to provide the panel strength by means of the placement of the horizontal and vertical bars between the surfaces of said panels.

Another object of the invention is to put forward a much more durable structure with the curtain and ceiling concretes being cast after the formation of the carcass structure, the layout of the curtain steel meshes, the placement of the tunnel moulds -in addition to many other intermediary steps- and the layout of all the installations required by the user, and to enable the user, in case he/she needs, to easily perform any alteration within the building. The user will be easily able to perform any kind of repair work within the modular building according to the invention, whereas the user may not even drive a nail in the buildings referred to as prefabricated.

Another object of the invention is to provide the strength of the concrete walls owing to the assembly of the curtain steel mesh reinforcement on the side surfaces of the carcass structure. Another object of the invention is to provide the panel strength owing to the placement of the horizontal and vertical metal bars between the panel surfaces.

Another object of the invention is to enable the loading of the modules, which are formed by joining said panels on the carcass structure that constitutes the main body, onto the transport means -trucks and trailers are preferably used as the transport means- via a lifter for the purpose of delivery of the same to the construction site, and to ensure that no sliding and deformation takes place in said module during said loading operation. The necessity that there will be no difference between the finished state of said modules produced in the factory environment and the state of the same upon delivery thereof to the construction site increases the importance of the loading operation. By means of a truck or trailer loading and unloading apparatus used according to the present invention, the modules are enabled to be lifted according to a regular weight and in a way to suit the centers of balance, and unloaded according to the same order at the construction site.

Another object of the invention is to enable, after the delivery of the modules formed in a factory environment to the construction site via the transport means, the combination of the same without the need for any labor at said site and in a way that no gap is left between the same.

Another object of the invention is to enable the elimination of the clearance formed in the upper sections of the module joint points and to enable a perfect engagement between the modules, due to the weight of the floor and wall surfaces of said modules formed in a factory environment. Another object of the invention is to put forward a system, which dictates the whole process of forming the modular building from the units produced in a factory environment, up to the delivery of the same to the construction site.

Another object of the invention is to enable, after the customer has selected the product with desired architectural features via the producer's internet site and/or the product catalogue and said request has been forwarded to the producer company, the establishment of the modular building within a very brief time on the area shown by the customer.

Another object of the invention is to enable the serial production of the panels according to certain standards and features and the keeping of the same ready for delivery and to enable only the combination and placement procedure to be carried out on the carcass structure in a factory environment, with a view to minimize the time that elapses between the placement of the order by the customer and the installation of the building on a site determined by the customer.

In order to achieve the aforesaid objects, the transportable modular building . system according to the invention comprises the process steps of receiving the order from a customer via at least one means for placing the purchase orders, forming the ceiling and the floor with sizes suitable for the transportation via a truck and trailer, by way of combination of the horizontal and vertical components obtained from the steel sheet or the alloys thereof and forming at least one carcass structure, conveying said carcass structure between the stations at each of which different procedures are performed, by means of at least one integrated band system and/or wheel conveyor system, and thus equipping the exterior surfaces and the interior in a way to suit the desired architectural features and to have all the installations ready in order to form at least one module, delivering said modules via at least one transport means to the construction site that is requested by the customer and for which the foundation has been laid, placing at least one module in the desired area and joining, on both sides of said module, the other modules delivered, thus forming a building with desired with and height.

In order to achieve the aforesaid objects, the invention discloses a module production method characterized in that the carcass structure, which is formed in a size suitable for the transport by a truck and trailer by joining the horizontal and vertical profiles obtained from the steel sheet or the alloys thereof, for the modules produced in the factory g

environment and combined as a single module or more than one module at the construction site with laid foundation in a desired region in order to form the finished building, is conveyed in all the production stages up to the formation of the module where it achieves its final form, between the stations at each of which different processes are carried out, by means of at least one band system and/or wheel conveyor system, and at least one panel is placed, in at least one station, between the ceiling and the floor of said carcass structure, said panel having a framework obtained by the horizontal, vertical or diagonal arrangement, at certain intervals, of the metal bars produced in different shapes according to the location at which they are to be used and formed from the steel sheet or the alloys thereof.

According to a preferred embodiment of the invention, at least one panel is placed between the ceiling and the floor of said carcass structure, said panel having a framework obtained by the horizontal, vertical or diagonal arrangement, at certain intervals, of the metal bars produced in different shapes according to the location at which they are to be used and formed from the steel sheet or the alloys thereof.

According to a preferred embodiment of the invention, said panels are previously prepared in the factory and are stored in a way to have entirely full structures, the structures with door spacing, the structures with window spacing and the structures with small window spacings for use in the toilets and bathrooms.

According to a preferred embodiment of the invention, at least one ready to use module is formed by placing the panels previously prepared and stored in a factory environment between the ceiling and the floor of said carcass structure according to the desired architectural features and by laying, at the factory, the wall tiles, cupboards and the installation outlets required for the kitchen and the bathroom inside said structure.

According to a preferred embodiment of the invention, the installations are fitted on the side surfaces of said carcass structure and following said fitting process, the concrete plates are used on the side surfaces and/or the concrete is cast onto said surfaces.

According to a preferred embodiment of the invention, to at least one side surface of said module unloaded to the construction site via any transport means - according to the size of the house demanded by the customer-, a second module is joined by means of the top-fitting system. In order to achieve all the advantages mentioned above, which will be understood from the following detailed description, the present invention brings about many conveniences based on its mentioned characteristics.

The structural and characteristic features and all the advantages of the invention will be more clearly understood from the figures provided below and the detailed description written with reference to these figures and thus, the evaluation must be made taking into consideration these figures and the detailed description.

Description of the Figures

In order to best understand the embodiment of the present invention and the advantages thereof along with the additional elements, it must be considered along with the figures for which the description is provided below.

Figure 1 is a perspective view of the carcass structure produced at the factory, constituting the main body and the framework of the building.

Figure 2 is a view illustrating the application, on said carcass structure, of the panel that is prepared in the factory environment according to the desired architectural features and is stored.

Figure 3a is a perspective view showing the interior structure of a module formed in a factory environment.

Figure 3b is a perspective view showing, from a different angle, the interior structure of a module formed in a factory environment.

Figure 4 is a view, according to side by side arrangement, of 3 modules, which have been prepared in a factory environment and are ready for delivery to the site requested by the customer.

Figure 5 is a perspective view of the trailer loading and unloading apparatus, which enables the modules produced in a factory environment to be loaded onto the trailers and unloaded from the same at the construction site in a problem-free manner. Figure 6 is a representative view showing the steps of the process of the system, which begins with the placement of a purchase order by the customer and ends with the placement of the modules on the requested area.

Figure 7 is an exemplary layout plan for the modules brought into a ready to use state in a factory environment.

Figure 8 is a bird's-eye view showing the module production stages via the band system developed to enable the module production within the factory.

Reference Numbers

10. Carcass structure 11. Horizontal profile

12. Vertical profile

13. Joining means

20. Panel

21. Framework 22. Frame

23. Horizontal bar

24. Vertical bar

25. Fill and insulation material

26. Electricity line 27. Electricity connection box

28. Connection ends

30. Module

31. Window/window spacing

32. Door/door spacing 33. Kitchen

34. Bathroom

35. Corner connection means

36. Lifting rings

40. Trailer loading and unloading apparatus 41. Handle

42. Hook

50. Means for placing the purchase order

51. Factory 52. Lifter

53. Transport means

54. Construction site

60. Band system/conveyor system 61. 1st station

62. 2nd station

63. 3rd station

Detailed Description of the Invention

In this detailed description, the modular building according to the invention and the preferred embodiments thereof will be explained in a manner only to enable a better understanding of the subject matter, without leading to any limiting effect.

With the module (30) production method according to the invention, it is aimed to complete all the stages from the formation of the carcass structure (10) through the completion of the fine works of the final module (30) to be prepared, by stopping by at the different stations (61 , 62, 63) according to predetermined times, via a band system (60) installed within the factory, and to enable a continuous production. An examination of all the prior art documents, patent applications and the present practice reveals that no study has been previously conducted concerning the module (30) production via a band system (60). Besides, it is obvious that the serial production realized by conveying said modules (30) with great volume and weight via band system (60) has emerged as a result of the researches and trials performed for a long time. It is possible to increase or, depending on the work load, to decrease the number of stations (61 , 62, 63) formed within the factory (51). In the light of the descriptions provided above, the movement of said module (30) between the stages of production (stations (61 , 62, 63)) is provided by means of a band system (60). As an alternative to the band system (60), the passages of the modules (30) between the stations (61 , 62, 63) may be provided by using a wheel conveyor system. At each station (61 , 62, 63), different activities are performed in order to form said module (30). In general, it is aimed to form said carcass structure (10) at the 1 st station (61), to lay all the installations inside the carcass structure (10) at the 2nd station (62) and to provide said module (30) with its final form at the 3rd station (63). In Figure 1 , a perspective view is provided of the carcass structure (10), which is produced at the factory (51) and which constitutes the main body and the framework of the building. Said carcass structure (10) is manufactured from sheet steel material with varying thicknesses. There are present the horizontal sheet profiles (11) that enable the structure (10) to be seated on the floor and at the end sections of said horizontal sheet profiles (11), the vertical sheet profiles (12) placed vertically along a vertical direction. Said carcass structure (10) constitutes the main body of the module (10) and its dimensions are arranged in a way to suit the truck and/or trailer transportation. In the upper section of said carcass structure (10), there are joining means (13), which are placed between the parallel horizontal profiles (11) and have different thicknesses than said profiles (11 , 12).

The carcass structure (10) shown in Figure 1 is in such a form to enable the positioning of various panels (20) produced previously according to certain sizes and standards for the modules (30) that comprise the building, and to allow the other modules (30) to be also connected. In order to join the modules (30) with each other, the corner joining means (35) are defined at the edges and the comers of the modules (30). With the aid of said corner joining means (35), another module (30) may be mounted next to a module (30) according to the top-fitting system. Here, on the other hand, what is important is to be able to form the finished building with desired width by combining the modules (30) in numerous ways, rather than the manner of fitting. All the clean water and wastewater inlets and outlets are placed on the floor of the carcass structure (10) and the structure is covered with insulation and filling materials (25). The floor covering materials with desired properties are coated on said filling materials (25).

In Figure 2, a view is provided, illustrating the application, on said carcass structure (10), of the panel (20) that is prepared in the factory environment (51) according to the desired architectural features and is stored. Said panels (20) are placed on the carcass structure (10) in accordance with the desired architectural features. The panels (20) are produced in different forms and stored, according to the place they are to be used on the carcass structure (10). For example, some panels (20) bear door spacings (32), while some others include window spacings (31). According to the preferred embodiments of the invention, said panels (20) are stored in a way to have entirely full structures, the structures with door spacing (32), the structures with window spacing (31) and the structures with small window spacings (31) for use in the toilets and bathrooms. The panel framework (21) shown in Figure 2 comprises a frame (22) and the metal bars (23) placed horizontally and vertically inside said frame (22). The number of the horizontal and vertical bars (23, 24) is determined according to the height of the building to be erected on said framework (21), which is also made preferably of steel and the alloys thereof and to the static calculations appropriate for the zone where the building is to be positioned. In order to provide insulation, the filling and insulation materials (25) are filled into the gaps formed by the bars (23, 24). Said materials (25) are applied preferably in the form of sheets formed from PVC or wooden materials cut into sizes to suit the gaps and in the form of plasterboard on the polyurethane foam.

In Figure 2, a perspective view is provided, of the placement of said panels (20) on the carcass structure (10). Here, especially the installations inside the building are previously connected to the panels (20) while in the form of a framework (21). For example, the electricity connection box (27) and electricity lines (21) required for the electricity installation, the switch boxes to which the switches that enable the control of lamps and various devices are connected, the boxes to which the phone and communication devices are connected and the lines (26) are assembled on the framework (21 ) prior to the completion of the panel (20). In order to associate said connections with each other between the panels (20), the connection ends (28) are provided to emerge from said panel (20) and said ends (28) are maintained in a state ready for connection. The installation connections of the modules (30) which are connected via said connection ends (28) are easily performed.

Similarly, the connection of the water connection valves with the water supply systems is performed before said (10) panel takes on its final form and the connection ends (28) are left outside to be connected with the other panels (20) and the primary plumbing.

Said panel frameworks (21) are prepared in a way to have windows, doors or spacings formed to suit numerous purposes, all depending on the location where the panels are to be used in the building. The walls are formed by applying the preferred materials on the framework (21), which is covered with the aforesaid filling materials (25). Said panels (20) are previously kept in stock in the factory environment (51), depending on the intensity of the demand. According to a preferred embodiment of the invention, after the installations are suitably fitted on the side surfaces of said carcass structure (10), the concrete plates are applied on said surfaces and/or the concrete is cast onto said surfaces.

According to an alternative embodiment of the invention, the columns may be formed on the carcass structure (10) by the use of the reduced-weight concrete and in this way, the strength of said module (30) may be increased.

In Figures 3a and 3b, the views of an exemplary module (30) prepared in a factory environment (51) are provided from different perspectives. Said module (30) may be designed in different forms, in order to provide a building embodiment having the architectural features as requested by the customer. In the module (30), all the wall tiles, cupboards and the installation outlets required for the kitchen (33) and the bathroom (34) are laid in the factory (51) and are provided to the customer in a ready form. In said module (30), there are located the door spacings (32) and the window spacings (31) to be used upon the combination with the other modules (30). The building types that fit the preference of the customer are obtained by way of combining more than one module (30) at the construction site.

In Figure 4, a view of 3 modules (30) is provided in side by side arrangement, said modules having all the processes completed in a factory environment (51) and being ready for delivery. The number of modules (30) may be increased according to the type of building demanded by the customer. Upon the combination of said modules (30), the building with desired width and architecture is obtained. Alternatively, said modules (30) may be disposed on top of each other to form multistorey building embodiments, according to the type of building demanded by the customer. The modules (30) thus obtained are both durable and stable structures, much different than a prefabricated building embodiment. Another important aspect is the inhibition of any deformation during the performance of the loading of said modules (30) from the factory (51) to the transport means (53) and of the unloading of the same at the construction site (54). By means of the handles (41) available on the top surface of the trailer loading and unloading apparatus (40) seen in Figure 5, said apparatus (40) is connected to a lifter (52) via steel ropes, and the connection hooks (42) located on the lower part of the apparatus (40) are engaged with the lifting rings (36) formed on the top sections of said modules (30), in order to perform the operations of loading the modules (30) to the trailer (53) and unloading the same from the trailer (53) and placing the same at the construction site (54). Owing to said apparatus (40), the weight and the balance point of the module (30) are adjusted by means of the connection hooks (42) disposed at certain intervals on the bottom surface of the module (30) and the lifting rings (36) formed on the top surfaces of the module (30), and thus it is ensured that no deformation takes place during the loading operations.

In Figure 6, a representative view is provided, showing the steps of the process of the system, which begins with the placement of a purchase order by the customer using any means for placing a purchase order (50) and ends with the placement of the modules (30) on the requested area (54). The customer places its order for the desired type of building using any means for ordering (50) (via internet site or by benefiting from the capacities of the modern technology, e.g. phone, or simply using a catalogue or product presentation brochures). Modular building models may possess the traditional house styles or modern building styles. Following the receipt of the purchase order at the enterprise, said panels (20) which are kept in stock are placed between the ceiling and the floor of the carcass structure (10) seen in Figure 1. Since said panels (20) are prepared and stored in different structures, which panel (20) is to be used in what part of the carcass structure (10) is known and this process is completed within a very short time by means of a kind of automation system. Said panels (20) are stored in a ready to use manner, equipped with all sorts of installations. The applications such as the floor coverings of the carcass structure (10), kitchen, bathroom and toilet are laid out in a way as preferred by the customer. The modules (30) that are prepared upon the completion of all the procedures are loaded onto the trailers (53) in an ordered manner by means of an apparatus (40) and are delivered to and placed on the site demanded by the customer. Following the placement of one module (30), second module (30) is placed next to the first module (30) by means of the top-fitting system. A different number of modules (30) are joined in the same manner, according to the width and the type of the finished building. In this way, the modules (30) which are produced at the factory (51) are joined at the construction site without the need being felt for any extra labor, and thus the finished building is obtained. Owing to the system according to the invention, the building ordered by the customer is supplied to the customer within one day in a state with all the procedures completed and ready to use. Differing alternative structures are employed for joining said modules (30) at the construction site (54). Said process of joining may also be performed by means of screwing, tightening and similar methods.

In order to avoid the occurrence of any violation of the traffic rules during the transport of the modular buildings via the highway, said modules (30) are made with dimensions that comply with the rules mentioned in the regulations for the highway transportation. For example, when it is preferred to utilize the highway transportation in order to deliver a finished module (30) on a trailer to the relevant site (54), the module is designed to have a width of 2 m - 2.60 m, a length of 6 m - 15 m and a height of 2 m - 3,5 m. For the buildings with more than one storey or in cases where the roof height exceeds said upper limit, the roof may be separately loaded onto the trailer (53) and upon the arrival at the construction site (54), the roof may be placed on the building by means of the trailer lifts. It is also possible to load a building in modular form such that it may fit into a vessel container.

According to an alternative embodiment of the invention, the columns may be formed on the carcass structure (10) using the reduced-weight concrete and thus the strength of said module (40) may be increased. The invention must be interpreted taking into account the protective scope as set forth in the claims, the detailed descriptions written above and the alternative embodiments.

The protective scope of this application is determined in the section of claims and the scope may by no means be limited to the description provided above only for exemplary purposes. It is obvious that a person skilled in the art may provide the innovation put forward by the invention also by using the similar embodiments and/or apply this embodiment to other fields used in the art for similar purposes. Consequently, such embodiments would obviously lack the criteria of inventive step and especially, of exceeding the state of the art.

Claims

1. A transportable modular building system for constructing the modules (30) that constitute a modular building, in an environment different than the construction site (54), preferably in a factory environment (51), and for placing the same on the construction site (54) for which the foundation is laid in a desired area, characterized in that it comprises the steps of,

- receiving the order from a customer via at least one means for placing the purchase orders (50),

- forming the ceiling and the floor with sizes suitable for the transportation via a truck and trailer, by way of combination of the horizontal and vertical profiles (11 , 12) obtained from the steel sheet or the alloys thereof and forming at least one carcass structure (10),

- conveying said carcass structure (10) between the stations (61 , 62, 63) at each of which different procedures are performed, by means of at least one integrated band system and/or wheel conveyor system (60), and thus equipping the exterior surfaces and the interior in a way to suit the desired architectural features and to have all the installations ready in order to form at least one module (30),

- delivering said modules (30) via at least one transport means (53) to the construction site (54) that is requested by the customer and for which the foundation has been laid,

- placing at least one module (30) in the desired area (54) and joining, on both sides of said module (30), the other modules (30) delivered, thus forming a building with desired with and height.

2. A system according to Claim 1 characterized in that the production line from the preparation of said carcass structure (10) through the module (30) formation where it assumes its final shape may comprise different number of stations.

3. A system according to Claim 1 characterized in that a truck or trailer is used as the transport means (53) for the delivery of said modules (30), which have been conveyed between the stations (61 , 62, 63) and have thus been provided with the final form thereof, to said construction site (54).

4. A system according to Claim 1 characterized in that said modules (30) are loaded onto said transport means (53) and unloaded and placed in the desired site (54) in an orderly manner via at least one trailer loading and unloading apparatus (40).

5. A system according to Claim 1 characterized in that the second module (30) is joined, via the top-fitting system, to at least one side surface of said module (30) delivered and unloaded via any transport means (53) to the construction site (54) -in accordance with the size of the building demanded by the customer.

6. The production method for the modules (30), which are constructed in a factory environment (51) and joined as a single module or more than one modules at the construction site (54) for which the foundation is laid in the desired area, in order to form the finished building, characterized in that

- the carcass structure (10), which is formed in a size suitable for the transport by a truck and trailer by joining the horizontal and vertical profiles (11 , 12) obtained from the steel sheet or the alloys thereof, is conveyed in all the production stages up to the formation of the module (30) where it achieves its final form, between the stations (61 , 62, 63) at each of which different processes are carried out, by means of at least one band system and/or wheel conveyor system (60), and at least one panel (20) is placed, in at least one station (61 , 62, 63), between the ceiling and the floor of said carcass structure (10), said panel having a framework (21) obtained by the horizontal, vertical or diagonal arrangement, at certain intervals, of the metal bars (23, 24) produced in different shapes according to the location at which they are to be used and formed from the steel sheet or the alloys thereof.

7. A method according to Claim 6 characterized in that the walls are formed by equipping the gaps formed by the metal bars (23, 24) inside said panel framework (21) with the filling and insulation materials (25), in order to provide insulation.

8. A method according to Claim 6 characterized in that said panels (20) are previously prepared in the factory and are stored in a way to have entirely full structures, the structures with door spacing (32), the structures with window spacing (31) and the structures with small window spacings (31 ) for use in the toilets and bathrooms.

9. A method according to Claim 6 characterized in that at least one ready to use module (30) is formed by placing the panels (20) previously prepared and stored in a factory environment (51) between the ceiling and the floor of said carcass structure (10) according to the desired architectural features and by laying, at the factory, the wall tiles, cupboards and the installation outlets required for the kitchen (33) and the bathroom (34) inside said structure.

10. A method according to Claim 6 characterized in that the installations are fitted on the side surfaces of said carcass structure (10) and following said fitting process, the concrete plates are used on the side surfaces and/or the concrete is cast onto said surfaces.

11. A method according to Claim 6 characterized in that the installations inside the building are connected to said panels (20) while still in framework (21) state.

12. A method according to Claim 6 characterized in that said panels (20) include in their ceiling parts, the installation connection ends (28) moved around the ceiling of said carcass structure (10).

13. A method according to Claim 6 characterized in that the clearance formed in the upper sections of the module (30) joint points is eliminated due to the weight of the floor and wall surfaces of said modules (30) and the modules are joined via the corner connection means (35) formed on the edges and the corners of the modules (30) in order to enable a perfect joint between said modules (30).