WO2014008551A1 - Modular buildings - Google Patents

Modular buildings Download PDF

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Publication number
WO2014008551A1
WO2014008551A1 PCT/AU2013/000774 AU2013000774W WO2014008551A1 WO 2014008551 A1 WO2014008551 A1 WO 2014008551A1 AU 2013000774 W AU2013000774 W AU 2013000774W WO 2014008551 A1 WO2014008551 A1 WO 2014008551A1
Authority
WO
WIPO (PCT)
Prior art keywords
building
units
modular
unit
type
Prior art date
Application number
PCT/AU2013/000774
Other languages
French (fr)
Inventor
Susan Unger
Original Assignee
1 Space Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2012902966A external-priority patent/AU2012902966A0/en
Priority claimed from AU2013201852A external-priority patent/AU2013201852B2/en
Priority claimed from AU2013205214A external-priority patent/AU2013205214B2/en
Application filed by 1 Space Pty Ltd filed Critical 1 Space Pty Ltd
Priority to AU2013289860A priority Critical patent/AU2013289860A1/en
Priority to CN201380042033.6A priority patent/CN104781480B/en
Publication of WO2014008551A1 publication Critical patent/WO2014008551A1/en
Priority to AU2018217199A priority patent/AU2018217199B2/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815—Elements not integrated in a skeleton
    • E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/005—Modulation co-ordination
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/02—Dwelling houses; Buildings for temporary habitation, e.g. summer houses
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H3/00—Buildings or groups of buildings for public or similar purposes; Institutions, e.g. infirmaries or prisons
    • E04H3/02—Hotels; Motels; Coffee-houses; Restaurants; Shops; Department stores
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H3/00—Buildings or groups of buildings for public or similar purposes; Institutions, e.g. infirmaries or prisons
    • E04H3/08—Hospitals, infirmaries, or the like; Schools; Prisons
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B2001/34876—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form with a sloping or barrel roof
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B2001/34892—Means allowing access to the units, e.g. stairs or cantilevered gangways
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
    • E04H9/14—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate against other dangerous influences, e.g. tornadoes, floods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather

Definitions

  • the present invention relates to modular buildings. Background
  • Known modular buildings comprise buildings formed of custom modified intermodal shipping containers, also known as sea containers.
  • shipping containers are of a fixed width - 2.4m (8ft) - and of a limited number of lengths - 6.1 m (20ft) or 12.2m (40ft). Accordingly areas or rooms inside building constructed of these containers are limited in their dimensions, according to the dimensions of the container. Making an area wider than the width of the container requires extensive structural modification of the containers, such as cutting through walls of the containers, which is undesirable and defeats the purpose of modularisation.
  • each container is individually customised to its particular application, which is counter to the concept of modularisation.
  • a building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of a plurality of end to end modular building units.
  • each of the units has the same dimensions.
  • a clear area within the building has a Cartesian dimension larger than an equivalent dimension of the modular units.
  • a clear room width is larger than the width of the modular unit.
  • the modular units are configured such that they can be assembled without structural modification.
  • each unit is of a unit type and each unit is configured according to its unit type.
  • the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration.
  • each bank is of a bank type, where each bank type is defined according to the unit types of its units.
  • the modular units are selected from a selection range and assembled in a relationship to form functional areas that meet a design requirement.
  • the units are stackable for transport and are able to be stacked in the building.
  • the outer units of the bank are mirrored.
  • each cluster comprises at least two banks of the same type.
  • a room in a cluster is defined by one of:
  • each cluster there are least three and preferably between six and twenty four banks in each cluster. Preferably there are ten to eighteen banks in each cluster. Preferably there are fifteen or less banks before there is access to the outside of the building or a fire escape.
  • each cluster comprises a plurality of levels, each level comprising a plurality of side by side banks, each bank formed of the end to end units.
  • the units of each level are stacked one atop another.
  • a level spanning unit is the height of at least two units.
  • each cluster is parallel, and linked laterally at the ends by access- ways.
  • at the end of each cluster is a stairway between levels or access to an outside of the building.
  • the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
  • areas are provided that span at least one modular building unit.
  • an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
  • a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor.
  • the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.
  • an internal portion of the building has a plurality of areas with the same type of use, with an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.
  • an outer portion of the building has a different use to the internal portion.
  • the inner portion has multiple bedrooms and the outer portion has a common use laundry
  • the building comprises a plurality of banks of usage areas.
  • a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks
  • a method of forming a building comprising:
  • each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
  • the modular building units are stackable for transport and stackable for assembly into the building.
  • construction of the building consists of assembly of the modular building units on a foundation and interconnection of the building units and their services. In particular additional construction is not required.
  • the modular building units of each type have one or more of the following predetermined: room size, room position, room orientation, internal walls, entrance/exit, windows, electrical/data services, plumbing services, and covered areas.
  • a building comprising assembled modular building units, where the units are assembled into one or more groups according to a type of unit used to form one or more types of area in the building, where one or more of the areas may be larger than the size of a building unit by spanning more than one unit, wherein the units have been formed to provide the areas when assembled.
  • a method of forming a building comprising:
  • each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
  • composition determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types;
  • one or more of the modular building units are packed into a container form for transport. ln an embodiment prior to assembly the modular building units, one or more of the modular building units are unpacked from container form to an assemble-able form, without need for structural modification. In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit.
  • the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit, or standard fractions thereof.
  • a standard fraction may comprise 1 ⁇ 4, 1/3, or 1 ⁇ 2.
  • determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration.
  • determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units.
  • determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.
  • the modular units are assembled without structural modification.
  • each modular unit is custom manufactured and assembled in a relationship with the other units to form the banks and clusters.
  • the determined space requirements comprise determining that the units are to be stacked in the building.
  • the units are stacked for transport.
  • panels are stacked in a unit for transport.
  • the determined composition comprises determining a configuration such that the outer units of the bank are mirrored. ln an embodiment the determined composition comprises determining a configuration such that each cluster comprises at least two banks of the same type.
  • the determined composition comprises determining a configuration such that there are least three and preferably between six and twenty four banks in each cluster. In an embodiment there are fifteen banks in each cluster. In an embodiment the determined composition comprises determining a configuration such that a level spanning unit is the height of at least two units.
  • the determined composition comprises determining a configuration such that each cluster is parallel, and linked laterally at the ends by access-ways.
  • the determined composition comprises determining a configuration such that at the end of each cluster is a stairway between levels or access to an outside of the building. In an embodiment the determined composition comprises determining a configuration such that there are banks of a type to provide common facilities at an end of the cluster.
  • the determined composition comprises determining a configuration such that there are banks of a type to provide a link at an end of the cluster to another end of another cluster.
  • the determined space requirements comprises determining a configuration such that internal spaces with a dimension longer than the length of a modular building unit are constrained to a maximum dimension without an internal floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.
  • the determined composition comprises determining a configuration such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
  • the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
  • the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor.
  • the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal service corridor therein, where there are a plurality of such modular building units adjacent one another so as to connect the service corridor portions to form the service corridor.
  • the determined composition comprises determining a configuration such that the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.
  • the determined space requirements comprises determining a configuration such that an internal portion of the building has repeated use areas, with an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.
  • the determined composition comprises determining a configuration such that an outer portion of the building has a different use to the internal portion. ln an embodiment the determined composition comprises determining a configuration such that the building comprises a plurality of banks of usage areas.
  • the determined composition comprises determining a configuration such that a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks.
  • each cluster comprising a plurality of end to end module banks, each module bank formed of a plurality of side to side modular building units.
  • Figure 1 is a schematic set of plan views showing a building according to an embodiment of the present invention
  • Figure 2 is an upper isometric view of a bank of modular building units of the building of Figure 1 ;
  • Figure 3 is a lower isometric view of the bank of Figure 2;
  • Figure 4 is an upper isometric view of a modular building unit of the building of Figure 1 , with a top face removed;
  • Figure 5 is an upper isometric view of a frame of the modular building unit of Figure 4.
  • Figure 6 is an end view of a cluster of the building of Figure 1 ;
  • Figure 7 is a side elevation of the cluster of the building of Figure 6;
  • Figure 8 is a plan view of a connecting portion of the building of Figure 1 ;
  • Figure 9 is a side elevation of the bank of Figure 3 in a transportation configuration
  • Figure 10A is an end view of the bank of Figure 3 in a transportation configuration
  • Figure 10B is an end view of an inside end of the unit of Figure 4 in a transportation configuration
  • Figure 1 1 is a plan view of a village comprising the building of Figure 1 ;
  • Figure 12A is a plan view of an embodiment of a bank of modular units and a cluster according to an embodiment of the present invention;
  • Figure 12B is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention.
  • Figure 12C is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention.
  • Figure 12D is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention.
  • Figure 13 is a plan view of a selection palette of modular building units according to an embodiment of the present invention.
  • Figure 14A is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12A;
  • Figure 14B is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12B;
  • Figure 14C is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12C;
  • Figure 14D is a plan view of an embodiment of a cluster according to an embodiment of the present invention.
  • Figure 15 is a schematic set of plan views showing a building according to an embodiment of the present invention.
  • Figure 16 is an exploded upper isometric view of an embodiment of an apartment building according to an embodiment of the present invention.
  • Figure 17A is a plan view of a ground storey of the apartment building of Figure 16;
  • Figure 17B is a plan view of a first storey of the apartment building of Figure 16
  • Figure 17C is a plan view of a second storey of the apartment building of Figure 16;
  • Figure 18 is a schematic set of isometric views showing examples of configurations of banks of modular units of Figure 16;
  • Figure 19 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention.
  • Figure 20 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention.
  • Figure 21 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention.
  • Figure 22 is a plan view of a fitted out and furnished building according to Figure 19;
  • Figure 23 is a plan view of a fitted out and furnished building according to Figure 20;
  • Figure 24 is a plan view of a fitted out and furnished building according to Figure 21 ;
  • Figure 25 is a schematic plan view of a complex which includes three buildings according to an embodiment of the present invention;
  • Figure 26 is a plan view of one of the buildings of Figure 25;
  • Figure 27 is a plan view of a building according to an embodiment of the present invention.
  • Figure 28 is a plan view of a building according to an embodiment of the present invention.
  • Figure 29 is a plan view of a building according to an embodiment of the present invention.
  • the building 10 is a precinct in a village 100.
  • the village 100 comprises a number of buildings 10.
  • the precinct may be a mine site accommodation complex, a hotel, hospice or offices.
  • the building 10 comprises one or more clusters 12.
  • a cluster comprises a plurality of similar usage areas.
  • a living quarters may comprise usage areas that may be bed and bath rooms.
  • the cluster comprises a plurality of banks 14, 14', 14", 14"' of modules.
  • a bank 14 of modules comprises a plurality of modular building units 16. Every unit in the bank, and preferably in the cluster has the same dimensions.
  • each bank 14 comprises three units 16 positioned end to end. Thus each bank has the same dimensions.
  • each bank 14 comprises a mirrored usage area on each side of a corridor, which will be described further below.
  • each bank may comprise living quarters on each side of a corridor.
  • each cluster comprises a plurality (in this case ten) of banks 14 in a side by side arrangement.
  • the cluster 12 comprises a bank 14"' on one side of the banks 14 and a bank 14" on either side of the banks 14"'/14.
  • the cluster 12 comprises a different usage type of bank 14' on either side of the plurality of banks 14".
  • the banks 14' comprises a vertical access unit, such as a stair way or elevator.
  • the clusters are offset and connected to each other by a cluster connection portion 20.
  • cluster 12' is substantially a mirror of cluster 12. The mirroring need not be identical as described more in relation to Figure 8.
  • a bank 14 may comprise a plurality of units 16 side by side as will be described in more detail below in relation to Figure 15.
  • each unit is of a unit type and each unit is configured according to its unit type.
  • the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration.
  • each bank is of a bank type, where each bank type is defined according to the unit types of its units.
  • a bank 14 is shown in more detail in Figures 2 and 3.
  • the bank 14 comprises unit 16A, which comprises a corridor 30 and entries 32 and 32'.
  • units 16B and 16C On either end of unit 16A are units 16B and 16C, each of these comprises a bedroom 34/34' and bathroom 36/36'.
  • the corridor may be a service corridor and rooms 32 and 32' are the bathroom and room 36 and 36' are the entries.
  • each unit 16 comprises a structural frame 40 in the shape of a rectangular prism. Longitudinally disposed end faces of the frame have vertically extending support members 44. Such a suitable frame is of the type used in a shipping container.
  • the longitudinal frame members have removable supports 52 extending vertically between them, which are used during transport of the unit and may be retained to provide additional support strength to the structure. However these supports 52 may also be removed leaving open the space 46 between the top and bottom longitudinal frame members. When the walls are removed leaving open space 46, this enables an area in the building to be larger than would otherwise be available.
  • a bottom face of the frame has transverse support members 42.
  • the top face of the frame may also have transverse support members. These support members 42 allow the floor of the unit to support sufficient weight and can also be used to mount a bottom level to a ground mounting system or to a level of units beneath.
  • the faces of the prism may have walls as shown in Figures 9, 10A and 10B.
  • an internal wall is provided inside of an outer wall.
  • the outer wall is preferably suitable for transport of the unit in a weather exposed condition.
  • the wall is formed of weathering steel, such as Cor-tenTM.
  • the wall is formed of a fibre reinforced polymer.
  • the outer wall is removable after transport or retained as a weather resistant outer wall in the building.
  • attachment points for lifting the unit to and from a transport vehicle, such as a truck, rail car, or ship, and for positioning in place in the building 10.
  • the attachment points are in the normal form of "castings" using for shipping containers.
  • the attachment points may also be used to secure adjacent units together in the building.
  • a portion of or the whole of the building is multistorey.
  • banks 14A, 14B and 14C each have respective banks 14AA, 14BB and 14CC on top so that there are two storeys.
  • Bank 14A has end corridor unit 16A with a door to the exterior of the building, and lower stair well units 16BA and 16BA'.
  • Above unit 16A in bank 14AA is an end corridor unit 16AB with a door to the exterior of the building and a hand rail.
  • a top part of the stair well units 16BA and 16BA' is in bank 14AA.
  • a unit may be two storeys high to span two stories with a stair well or elevator shaft between the stories.
  • An embodiment of a roof 60 is in two parts and spans bank 14AA. Each part is longer than the respective end building unit and partly covers unit 16AB.
  • a cluster connection portion 20 is shown in more detail. It can be seen that the end banks 14A are spaced apart, both axially and longitudinally.
  • a bridging bank 22 of units is provided to connect the banks 14A together.
  • Each bank 14A abuts a respective half of the bank 22.
  • the clusters are generally mirrored. However one of the clusters (or both if desired) may be provided with an overlapping bank 24 that overlaps the lower bank 14A.
  • the overlapping bank may provide a usage not required internally of the cluster or not required in each cluster.
  • a laundry or lockers may be provided in the bank 24.
  • Other variations include services (such as plumbing, electrical, air conditioning) or if made larger common access rooms can be provided, or universal access rooms or suites. Banks may be wider than one unit.
  • the bank 14D is one unit wide for a first type of use.
  • the bank 14E is two units wide for a second type of use.
  • the bank is three units wide for a third type of use. It can be seen that the banks of whichever type are repeated within the cluster and at the end of each cluster there are different banks.
  • Wider banks or areas spread over a plurality of banks can allow for a greater range of usages or areas not constrained by building unit size size, which is the case with standard shipping containers, without structural modification of the container(s) particularly when the side walls are removed to produce open areas 46 between the banks of a larger dimension than the width of the unit. In other words a room can span two or more units.
  • Clusters may have more than one type of bank.
  • the cluster 12G comprises types 14D, 14E and 14F.
  • the end banks can be verandas in a single story building or can be stair wells in a multistory building. Alternatively they can be common areas. If secured during a storm or cyclone secured accessways will still allow movement within the building.
  • a bank in the building may be a cyclone / hurricane shelter.
  • FIG. 13 a plurality, in this example, 13 different types of unit can be available as stock units. This allows the building to be modularly design the building and for it to be built by following the following process:
  • each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
  • composition determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types;
  • each of the types of unit is, by way of example:
  • 0 - service corridor with a 'wet area', for example a bathroom, on either side of the service corridor;
  • plain white areas may have a concrete floor
  • vertical shading may be a timber or similar floor
  • dotted areas are "dry area” floors (eg carpet)
  • square pattern is a "wet area” floor, with appropriate services (eg vinyl floors).
  • the bank 14D has type 5 units on either side of a type 0 unit.
  • the required number of units can be mass manufactured according to the requirements and then transported to the building site for assembly.
  • one or more of the modular building units are packed into a container form for transport.
  • one or more of the modular building units are unpacked from container form to an assemble-able form, without need for structural modification.
  • the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit. In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit, or standard fractions thereof.
  • a standard fraction may comprise 1 ⁇ 4, 1 /3, or 1 ⁇ 2.
  • the grid is based on a unit size suitable for transport.
  • determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration. In an embodiment determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units. In an embodiment determining the configuration comprises selecting units such that selection of the unit designate whether a room in the building is a "wet area", such as for example a bathroom, including the wall and floor treatments and furnishings in the room. In an embodiment determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.
  • the determined space requirements comprise determining that the units are to be stacked in the building.
  • the determined composition comprises determining a configuration such that the outer units of the bank are mirrored.
  • the determined composition comprises determining a configuration such that each cluster comprises at least two banks of the same type.
  • the determined space requirements comprises determining a configuration such that internal spaces with a dimension longer than the length of a modular building unit are constrained to a maximum dimension without an internal floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.
  • the determined composition comprises determining a configuration such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
  • the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
  • the area of the building which is a multiple of a floor area of a modular building unit, where the floor area may span a plurality of levels;
  • the modular building units used may be manufactured ready for assembly into the building, transported to the building site in a stackable manner and may be assembled into the building in a stackable manner.
  • Figures 14A to 14C show alternative lay outs of a dwelling.
  • the dwelling may be stand-alone in a complex of similar dwellings or it may be a part of a cluster 18.
  • Figure 14A comprises one modular building unit fitted out with an entry, bedroom and bathroom. It might be for example a hotel room or a single worker's quarters in an accommodation village.
  • Figure 14B comprises of two side by side modular building units in a bank and is fitted out with an entry, bedroom, bathroom kitchen, living room and study. It might be a hotel suite or a supervisor's quarters in an accommodation village.
  • Figure 14C comprises of three modular building units in a bank fitted out with an entry, bedroom, bathroom, kitchen, laundry, dinning theatre, study and living room. It might be a hotel penthouse suite or a manger's quarters in an accommodation village.
  • banks of these dwellings 102 may be arranged into buildings in an accommodation precinct building or hotel building 100, with connecting pathways/corridors 104.
  • This floor plan may be repeated with stacked banks of building units many levels high.
  • FIG. 15 there is shown a set of buildings 10A, 10B, 10C and 10D, each of which comprise an end to end bank 14 or an alternative side to side bank 14A.
  • the plurality of units 16 are side by side and the banks abut end to end.
  • Building 10A is one building in a cluster of buildings that have a dwelling density of R60, that is 60 dwellings are permitted in a 1 hectare (10000m2) area of land.
  • Building 10B is one building in a cluster of buildings that have a dwelling density of R40, that is 40 dwellings are permitted in a 1 hectare area of land. This building has two alternate banks 14A of three units side by side on a first level and one alternate bank of three units on a second level and one alternate bank of three units on a third level.
  • Building 10C is one building in a cluster of buildings that have a dwelling density of R30, that is 30 dwellings are permitted in a 1 hectare area of land.
  • Building 10D is one building in a cluster of buildings that have a dwelling density of R20, that is 20 dwellings are permitted in a 1 hectare area of land.
  • Figure 25 is another example of a complex 200 with three buildings of R40 density.
  • Figure 26 shows the make up of each building from the unit types 3, 4, 2 (in the first alternative bank of 3 units) and unit types 8, 3, and 8 (in the second alternative bank of units). It can be seen the areas of units 3 and 4 are combined to form a large room and unit 4 and 3 have a joining doorway and that both of units 8 have joining door ways with unit 3. It can also be seen that the right side unit 8 is a mirror of left side unit 8.
  • a three story apartment building 1 10 is shown. In this embodiment the banks are formed of side by side modular units. In this case the widths of bank are the same, but in an alternative embodiment the width need not be the same in each bank.
  • the ground level is 1 12, the first level is 1 14 and the second level is 1 16.
  • Figure 18 shows the removal of side/end panels used in transport in each back of the ground 1 12, first 1 14 and second 1 16 levels. This allows for larger internal areas or in the case of the units in the ground level side access to the units, such as for car parking spaces.
  • Figure 17 A shows the floor plan of the ground level 1 12 using the types of modular units in Figure 13.
  • Figure 17B shows the floor plan of the first level 1 14 and Figure 17C shows the floor plan of the second level 116.
  • Figure 19 shows an alternative building comprising a bank of units in a side by side arrangement.
  • notional unit types are 5, 8 and 9, with 2 of type 5 and type 8 being used, along with the removal of external walls between types 5 and 9, so as to produce a larger area internal to units 5 and 9.
  • the external wall units may be surplus to the units transported.
  • this building can be transported on a single move using a single vehicle (truck / road train).
  • Figure 22 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.
  • Figure 20 shows an alternative building comprising two banks of units in a side by side arrangement, with the banks being offset by a unit width and with the units end to end.
  • notional unit types are 1 , 2, 3, 4, 7, and 8, with 1 of type 1 , 2 of type 2, 2 of type 3, 1 of type 4, 3 of type 7 and 1 of type 8 being used, along with the removal of external walls between the 2 type 2 units and the type 4 and 8 units, so as to produce a larger area internal to units 2-2 and 4-8.
  • the external wall units are surplus to the units transported.
  • this building can be transported on a single move using two vehicles (truck / road train).
  • Figure 23 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.
  • Figure 21 shows an alternative building comprising three banks of units in a side by side arrangement.
  • two banks are perpendicular and a shorter bank is end to end with one bank and offset from the other bank by a unit width.
  • notional unit types are 1 , 2, 3, 4, 5, 7, 8 and 9, with 2 of type 1 , 2 of type 2, 3 of type 3, 1 of type 4, 2 of type 5, 1 of type 7, 2 of type 8 and 1 of type 9 being used, along with the removal of external walls between types 1 and 1 , 2 and 2, 3 and 3 and 3 and 4 so as to produce a larger area internal to units 1 -1 2-2, 3-3, 3-4.
  • the external wall units are surplus to the units transported.
  • this building can be transported on a single move using three vehicles (truck / road train).
  • Figure 24 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.
  • Figure 27 is another example building of R20 density and is assembled from four alternative banks of three side by side units. The first bank is assembled from unit types 1 , 1 and 0. The next bank is assembled from unit types 4, 3, and 5'. The next bank is assembled from unit types 2, 2, and 0. The final bank is assembled from unit types 5', 5', and 5'.
  • Figure 28 is another example building of R30 density where each level has a common area 202 and two individual bedrooms adjacent to each staircase.
  • Figure 29 is a further example building of R30 density similar to Figure 28 with a different floor plan.
  • the transportability of the units may also be useful not just to construct a build, but also to move the building to a different location, or to break up the building and reuse the modular units on one or more other buildings of different design.
  • the modular building unit are suitable for transport by road, rail and ship.
  • the dimensions of each unit may be for example 3.3m x 6m, 3.4m x 6m, 3.6m x 7.2m, 3.7m x 7.3m, or otherwise. Modifications may be made to the present invention with the context of that described and shown in the drawings. Such modifications are intended to form part of the invention described in this specification.

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Abstract

A building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of end to end modular building units.

Description

Modular Buildings
The present invention relates to modular buildings. Background
Known modular buildings comprise buildings formed of custom modified intermodal shipping containers, also known as sea containers. However shipping containers are of a fixed width - 2.4m (8ft) - and of a limited number of lengths - 6.1 m (20ft) or 12.2m (40ft). Accordingly areas or rooms inside building constructed of these containers are limited in their dimensions, according to the dimensions of the container. Making an area wider than the width of the container requires extensive structural modification of the containers, such as cutting through walls of the containers, which is undesirable and defeats the purpose of modularisation.
Furthermore each container is individually customised to its particular application, which is counter to the concept of modularisation.
Reference to prior art documents is not an admission that they form part of the common general knowledge of a skilled person in any jurisdiction.
Summary of the Invention
In this specification the terms "comprising" or "comprises" are used inclusively and not exclusively or exhaustively.
According to the present invention there is provided a building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of a plurality of end to end modular building units. In an embodiment each of the units has the same dimensions.
In an embodiment a clear area within the building has a Cartesian dimension larger than an equivalent dimension of the modular units. For example a clear room width is larger than the width of the modular unit. ln an embodiment the modular units are configured such that they can be assembled without structural modification.
In an embodiment each unit is of a unit type and each unit is configured according to its unit type. In an embodiment the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration. In an embodiment each bank is of a bank type, where each bank type is defined according to the unit types of its units. In an embodiment the modular units are selected from a selection range and assembled in a relationship to form functional areas that meet a design requirement.
In an embodiment the units are stackable for transport and are able to be stacked in the building.
Preferably the outer units of the bank are mirrored.
In an embodiment each cluster comprises at least two banks of the same type. In an embodiment a room in a cluster is defined by one of:
a portion of a modular unit;
a bank;
a plurality of banks;
a plurality of portions of modular units spaning a plurality of banks.
In an embodiment there are least three and preferably between six and twenty four banks in each cluster. Preferably there are ten to eighteen banks in each cluster. Preferably there are fifteen or less banks before there is access to the outside of the building or a fire escape.
In an embodiment there are four clusters. In an embodiment there are four clusters of the same height and a fifth cluster of a greater height that is closer to a transport node. ln an embodiment each cluster comprises a plurality of levels, each level comprising a plurality of side by side banks, each bank formed of the end to end units. The units of each level are stacked one atop another. In an embodiment a level spanning unit is the height of at least two units.
In an embodiment each cluster is parallel, and linked laterally at the ends by access- ways. In an embodiment at the end of each cluster is a stairway between levels or access to an outside of the building.
In an embodiment there are banks of a type to provide common facilities at an end of the cluster.
In an embodiment internal spaces with a dimension longer than the length of a modular building unit are constrained to a maximum dimension without an internal floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.
In an embodiment the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
In an embodiment areas are provided that span at least one modular building unit.
In an embodiment an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units. In an embodiment a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor. In an embodiment the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored. ln an embodiment an internal portion of the building has a plurality of areas with the same type of use, with an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.
In an embodiment an outer portion of the building has a different use to the internal portion. For example the inner portion has multiple bedrooms and the outer portion has a common use laundry In an embodiment the building comprises a plurality of banks of usage areas.
In an embodiment a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks
In an embodiment there is a vertical access between levels, such as stairway or elevator between levels
According to the present invention there is provided a method of forming a building comprising:
determining the usage requirements of the building in terms of types of areas (including rooms) within the building from a plurality of available types;
determining the space requirements of the building in terms of the number of each type of area within the building and size of each type of area, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements;
manufacturing the modular building units according to the determined type and number;
transporting the modular building units to a building site; and
assembling the modular units into the building. In an embodiment the modular building units are stackable for transport and stackable for assembly into the building. ln an embodiment construction of the building consists of assembly of the modular building units on a foundation and interconnection of the building units and their services. In particular additional construction is not required.
In an embodiment the modular building units of each type have one or more of the following predetermined: room size, room position, room orientation, internal walls, entrance/exit, windows, electrical/data services, plumbing services, and covered areas.
Also according the present invention there is provided a building comprising assembled modular building units, where the units are assembled into one or more groups according to a type of unit used to form one or more types of area in the building, where one or more of the areas may be larger than the size of a building unit by spanning more than one unit, wherein the units have been formed to provide the areas when assembled.
According to the present invention there is provided a method of forming a building comprising:
determining the usage requirements of the building in terms of types of areas within the building, from a plurality of available types;
determining the space requirements of the building in terms of the number of each type of area within the building and size of each type of area, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types;
obtaining the modular building units according to the determined type and number; transporting the modular building units to a building site; and
assembling the modular units into the building.
In an embodiment prior to transport one or more of the modular building units are packed into a container form for transport. ln an embodiment prior to assembly the modular building units, one or more of the modular building units are unpacked from container form to an assemble-able form, without need for structural modification. In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit.
In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit, or standard fractions thereof. A standard fraction may comprise ¼, 1/3, or ½.
In an embodiment determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration.
In an embodiment determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units.
In an embodiment determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.
In an embodiment the modular units are assembled without structural modification.
In an embodiment each modular unit is custom manufactured and assembled in a relationship with the other units to form the banks and clusters.
In an embodiment the determined space requirements comprise determining that the units are to be stacked in the building. In an embodiment the units are stacked for transport. In an embodiment panels are stacked in a unit for transport.
Preferably the determined composition comprises determining a configuration such that the outer units of the bank are mirrored. ln an embodiment the determined composition comprises determining a configuration such that each cluster comprises at least two banks of the same type.
In an embodiment the determined composition comprises determining a configuration such that a room in a cluster is defined by one of:
a portion of a modular unit;
a bank;
a plurality of banks;
a plurality of portions of modular units spaning a plurality of banks.
In an embodiment the determined composition comprises determining a configuration such that there are least three and preferably between six and twenty four banks in each cluster. In an embodiment there are fifteen banks in each cluster. In an embodiment the determined composition comprises determining a configuration such that a level spanning unit is the height of at least two units.
In an embodiment the determined composition comprises determining a configuration such that each cluster is parallel, and linked laterally at the ends by access-ways.
In an embodiment the determined composition comprises determining a configuration such that at the end of each cluster is a stairway between levels or access to an outside of the building. In an embodiment the determined composition comprises determining a configuration such that there are banks of a type to provide common facilities at an end of the cluster.
In an embodiment the determined composition comprises determining a configuration such that there are banks of a type to provide a link at an end of the cluster to another end of another cluster.
In an embodiment the determined space requirements comprises determining a configuration such that internal spaces with a dimension longer than the length of a modular building unit are constrained to a maximum dimension without an internal floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.
In an embodiment the determined composition comprises determining a configuration such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
In an embodiment the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
In an embodiment the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor.
In an embodiment the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal service corridor therein, where there are a plurality of such modular building units adjacent one another so as to connect the service corridor portions to form the service corridor.
In an embodiment the determined composition comprises determining a configuration such that the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.
In an embodiment the determined space requirements comprises determining a configuration such that an internal portion of the building has repeated use areas, with an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.
In an embodiment the determined composition comprises determining a configuration such that an outer portion of the building has a different use to the internal portion. ln an embodiment the determined composition comprises determining a configuration such that the building comprises a plurality of banks of usage areas.
In an embodiment the determined composition comprises determining a configuration such that a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks.
According to the present invention there is provided a building formed by performing the above method.
Also according to the present invention there is a building structure formed of one or more elongate clusters, each cluster comprising a plurality of end to end module banks, each module bank formed of a plurality of side to side modular building units.
Description of Drawings
In order to provide a better understanding of the present invention example embodiments will now be described in reference to the accompanying drawings, in which:
Figure 1 is a schematic set of plan views showing a building according to an embodiment of the present invention;
Figure 2 is an upper isometric view of a bank of modular building units of the building of Figure 1 ;
Figure 3 is a lower isometric view of the bank of Figure 2;
Figure 4 is an upper isometric view of a modular building unit of the building of Figure 1 , with a top face removed;
Figure 5 is an upper isometric view of a frame of the modular building unit of Figure 4;
Figure 6 is an end view of a cluster of the building of Figure 1 ;
Figure 7 is a side elevation of the cluster of the building of Figure 6;
Figure 8 is a plan view of a connecting portion of the building of Figure 1 ;
Figure 9 is a side elevation of the bank of Figure 3 in a transportation configuration;
Figure 10A is an end view of the bank of Figure 3 in a transportation configuration;
Figure 10B is an end view of an inside end of the unit of Figure 4 in a transportation configuration;
Figure 1 1 is a plan view of a village comprising the building of Figure 1 ; Figure 12A is a plan view of an embodiment of a bank of modular units and a cluster according to an embodiment of the present invention;
Figure 12B is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention;
Figure 12C is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention;
Figure 12D is a plan view of an alternative embodiment of a bank of modular units and a cluster according to an embodiment of the present invention;
Figure 13 is a plan view of a selection palette of modular building units according to an embodiment of the present invention;
Figure 14A is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12A;
Figure 14B is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12B;
Figure 14C is a plan view of an embodiment of a fitted out unit of the type in the bank of Figure 12C;
Figure 14D is a plan view of an embodiment of a cluster according to an embodiment of the present invention;
Figure 15 is a schematic set of plan views showing a building according to an embodiment of the present invention;
Figure 16 is an exploded upper isometric view of an embodiment of an apartment building according to an embodiment of the present invention;
Figure 17A is a plan view of a ground storey of the apartment building of Figure 16;
Figure 17B is a plan view of a first storey of the apartment building of Figure 16; Figure 17C is a plan view of a second storey of the apartment building of Figure 16;
Figure 18 is a schematic set of isometric views showing examples of configurations of banks of modular units of Figure 16;
Figure 19 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention;
Figure 20 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention;
Figure 21 is a schematic set of a plan view and perspective views showing an alternative building according to an embodiment of the present invention;
Figure 22 is a plan view of a fitted out and furnished building according to Figure 19; Figure 23 is a plan view of a fitted out and furnished building according to Figure 20;
Figure 24 is a plan view of a fitted out and furnished building according to Figure 21 ; Figure 25 is a schematic plan view of a complex which includes three buildings according to an embodiment of the present invention;
Figure 26 is a plan view of one of the buildings of Figure 25;
Figure 27 is a plan view of a building according to an embodiment of the present invention;
Figure 28 is a plan view of a building according to an embodiment of the present invention; and
Figure 29 is a plan view of a building according to an embodiment of the present invention.
Description of Preferred Embodiments
Referring to Figures 1 and 1 1 there is shown a building 10 according to an embodiment of the present invention. In this case the building 10 is a precinct in a village 100. The village 100 comprises a number of buildings 10. For example the precinct may be a mine site accommodation complex, a hotel, hospice or offices.
The building 10 comprises one or more clusters 12. In this embodiment a cluster comprises a plurality of similar usage areas. For example in an accommodation complex a living quarters may comprise usage areas that may be bed and bath rooms. The cluster comprises a plurality of banks 14, 14', 14", 14"' of modules. A bank 14 of modules comprises a plurality of modular building units 16. Every unit in the bank, and preferably in the cluster has the same dimensions. In this embodiment each bank 14 comprises three units 16 positioned end to end. Thus each bank has the same dimensions. Further in this embodiment each bank 14 comprises a mirrored usage area on each side of a corridor, which will be described further below. For example each bank may comprise living quarters on each side of a corridor. In this embodiment each cluster comprises a plurality (in this case ten) of banks 14 in a side by side arrangement. Further the cluster 12 comprises a bank 14"' on one side of the banks 14 and a bank 14" on either side of the banks 14"'/14. Further still the cluster 12 comprises a different usage type of bank 14' on either side of the plurality of banks 14". In this embodiment the banks 14' comprises a vertical access unit, such as a stair way or elevator. In this embodiment the clusters are offset and connected to each other by a cluster connection portion 20. In this embodiment cluster 12' is substantially a mirror of cluster 12. The mirroring need not be identical as described more in relation to Figure 8. In an alternative or in addition a bank 14 may comprise a plurality of units 16 side by side as will be described in more detail below in relation to Figure 15. In an embodiment each unit is of a unit type and each unit is configured according to its unit type. In an embodiment the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration. In an embodiment each bank is of a bank type, where each bank type is defined according to the unit types of its units.
A bank 14 is shown in more detail in Figures 2 and 3. In this embodiment the bank 14 comprises unit 16A, which comprises a corridor 30 and entries 32 and 32'. On either end of unit 16A are units 16B and 16C, each of these comprises a bedroom 34/34' and bathroom 36/36'. In an alternative the corridor may be a service corridor and rooms 32 and 32' are the bathroom and room 36 and 36' are the entries. Also referring to Figures 4 and 5, each unit 16 comprises a structural frame 40 in the shape of a rectangular prism. Longitudinally disposed end faces of the frame have vertically extending support members 44. Such a suitable frame is of the type used in a shipping container. The longitudinal frame members have removable supports 52 extending vertically between them, which are used during transport of the unit and may be retained to provide additional support strength to the structure. However these supports 52 may also be removed leaving open the space 46 between the top and bottom longitudinal frame members. When the walls are removed leaving open space 46, this enables an area in the building to be larger than would otherwise be available. A bottom face of the frame has transverse support members 42. The top face of the frame may also have transverse support members. These support members 42 allow the floor of the unit to support sufficient weight and can also be used to mount a bottom level to a ground mounting system or to a level of units beneath.
For transport, and if desired to be used in the assembled building, the faces of the prism may have walls as shown in Figures 9, 10A and 10B. In one embodiment an internal wall is provided inside of an outer wall. The outer wall is preferably suitable for transport of the unit in a weather exposed condition. In an embodiment the wall is formed of weathering steel, such as Cor-ten™. In an embodiment the wall is formed of a fibre reinforced polymer. In an embodiment the outer wall is removable after transport or retained as a weather resistant outer wall in the building.
Also for transport the corners 50 of the unit 16 may have attachment points for lifting the unit to and from a transport vehicle, such as a truck, rail car, or ship, and for positioning in place in the building 10. The attachment points are in the normal form of "castings" using for shipping containers. In the sides of the longitudinal frame members 40 there are fork pockets for receiving tines of a forklift, the same as is a normal shipping container. The attachment points may also be used to secure adjacent units together in the building.
In an embodiment a portion of or the whole of the building is multistorey. In the embodiment shown in Figures 6 and 7 there are two stories. There may be more stories if desired. As shown, banks 14A, 14B and 14C each have respective banks 14AA, 14BB and 14CC on top so that there are two storeys. Bank 14A has end corridor unit 16A with a door to the exterior of the building, and lower stair well units 16BA and 16BA'. Above unit 16A in bank 14AA is an end corridor unit 16AB with a door to the exterior of the building and a hand rail. A top part of the stair well units 16BA and 16BA' is in bank 14AA. A unit may be two storeys high to span two stories with a stair well or elevator shaft between the stories. An embodiment of a roof 60 is in two parts and spans bank 14AA. Each part is longer than the respective end building unit and partly covers unit 16AB.
Referring to Figure 8 a cluster connection portion 20 is shown in more detail. It can be seen that the end banks 14A are spaced apart, both axially and longitudinally.
Opposite longitudinal walls of the respective clusters are aligned in this embodiment. A bridging bank 22 of units is provided to connect the banks 14A together. Each bank 14A abuts a respective half of the bank 22. The clusters are generally mirrored. However one of the clusters (or both if desired) may be provided with an overlapping bank 24 that overlaps the lower bank 14A. In this case the overlapping bank may provide a usage not required internally of the cluster or not required in each cluster. For example a laundry or lockers may be provided in the bank 24. Other variations include services (such as plumbing, electrical, air conditioning) or if made larger common access rooms can be provided, or universal access rooms or suites. Banks may be wider than one unit. For example in Fig 12A the bank 14D is one unit wide for a first type of use. In Figure 12B the bank 14E is two units wide for a second type of use. In Figure 12C the bank is three units wide for a third type of use. It can be seen that the banks of whichever type are repeated within the cluster and at the end of each cluster there are different banks.
Wider banks or areas spread over a plurality of banks can allow for a greater range of usages or areas not constrained by building unit size size, which is the case with standard shipping containers, without structural modification of the container(s) particularly when the side walls are removed to produce open areas 46 between the banks of a larger dimension than the width of the unit. In other words a room can span two or more units.
Clusters may have more than one type of bank. For example in Figure 12D, the cluster 12G comprises types 14D, 14E and 14F. In these examples the end banks can be verandas in a single story building or can be stair wells in a multistory building. Alternatively they can be common areas. If secured during a storm or cyclone secured accessways will still allow movement within the building. In an embodiment a bank in the building may be a cyclone / hurricane shelter.
Referring to Figure 13 a plurality, in this example, 13 different types of unit can be available as stock units. This allows the building to be modularly design the building and for it to be built by following the following process:
determining the usage requirements of the building in terms of types of areas within the building, from a plurality of available types;
determining the space requirements of the building in terms of the number of each type of area within the building and size of each area of each type, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types;
obtaining the modular building units according to the determined type and number; transporting the modular building units to a building site; and
assembling the modular units into the building. ln Figure 13 each of the types of unit is, by way of example:
0 - service corridor, with a 'wet area', for example a bathroom, on either side of the service corridor;
1 - carport;
2 - ■ alfresco area;
3 - ■ living room;
4 - ■dining room with kitchen bench;
5 - ■ study or bedroom with veranda;
6 - ■ bathroom/laundry with veranda;
7 - ■ bathroom/laundry with passage
8 - ■ bedroom with bathroom ;
9 - ■ meals room with kitchen;
10 - alfresco with barbeque area;
1 1 - entry veranda with stairs; and
12 - stairs entry and living area.
In this example, plain white areas may have a concrete floor, vertical shading may be a timber or similar floor, dotted areas are "dry area" floors (eg carpet) and square pattern is a "wet area" floor, with appropriate services (eg vinyl floors).
In Figure 12A, the bank 14D has type 5 units on either side of a type 0 unit.
Alternatively if a unit of non stock type is required the required number of units can be mass manufactured according to the requirements and then transported to the building site for assembly.
In an embodiment prior to transport one or more of the modular building units are packed into a container form for transport. In an embodiment prior to assembly the modular building units, one or more of the modular building units are unpacked from container form to an assemble-able form, without need for structural modification.
In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit. In an embodiment the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit, or standard fractions thereof. A standard fraction may comprise ¼, 1 /3, or ½. In an embodiment the grid is based on a unit size suitable for transport.
In an embodiment determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration. In an embodiment determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units. In an embodiment determining the configuration comprises selecting units such that selection of the unit designate whether a room in the building is a "wet area", such as for example a bathroom, including the wall and floor treatments and furnishings in the room. In an embodiment determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.
In an embodiment the determined space requirements comprise determining that the units are to be stacked in the building.
Preferably the determined composition comprises determining a configuration such that the outer units of the bank are mirrored. In an embodiment the determined composition comprises determining a configuration such that each cluster comprises at least two banks of the same type.
In an embodiment the determined composition comprises determining a configuration such that a room in a cluster is defined by one of:
a portion of a modular unit;
a bank;
a plurality of banks;
a plurality of portions of modular units spaning a plurality of banks.
In an embodiment the determined space requirements comprises determining a configuration such that internal spaces with a dimension longer than the length of a modular building unit are constrained to a maximum dimension without an internal floor to ceiling support structure of the length of the modular building structure less the thickness of the support structure.
In an embodiment the determined composition comprises determining a configuration such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
In an embodiment the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
In an embodiment designing a building comprises:
determining the area of the building which is a multiple of a floor area of a modular building unit, where the floor area may span a plurality of levels;
determining the types of uses of rooms in the building, subject to a constraint of the determined area of the building;
i) selecting a module type according to one or more of the determined types of room usage from a plurality of available module types;
ii) selecting a number of the selected module type to accommodate a desired area of the room usage or usages for which the module type was selected; and
iii) repeating the selection steps i) and ii)) so that each of the types of use of the rooms is accommodated in the area available within the building. The modular building units used may be manufactured ready for assembly into the building, transported to the building site in a stackable manner and may be assembled into the building in a stackable manner.
Figures 14A to 14C show alternative lay outs of a dwelling. The dwelling may be stand-alone in a complex of similar dwellings or it may be a part of a cluster 18.
Figure 14A comprises one modular building unit fitted out with an entry, bedroom and bathroom. It might be for example a hotel room or a single worker's quarters in an accommodation village. Figure 14B comprises of two side by side modular building units in a bank and is fitted out with an entry, bedroom, bathroom kitchen, living room and study. It might be a hotel suite or a supervisor's quarters in an accommodation village. Figure 14C comprises of three modular building units in a bank fitted out with an entry, bedroom, bathroom, kitchen, laundry, dinning theatre, study and living room. It might be a hotel penthouse suite or a manger's quarters in an accommodation village. As shown in Figure 14D, in an embodiment, banks of these dwellings 102 may be arranged into buildings in an accommodation precinct building or hotel building 100, with connecting pathways/corridors 104. This floor plan may be repeated with stacked banks of building units many levels high.
Referring to Figure 15 there is shown a set of buildings 10A, 10B, 10C and 10D, each of which comprise an end to end bank 14 or an alternative side to side bank 14A. In an alternative bank 14A, the plurality of units 16 are side by side and the banks abut end to end.
Building 10A is one building in a cluster of buildings that have a dwelling density of R60, that is 60 dwellings are permitted in a 1 hectare (10000m2) area of land.
Building 10B is one building in a cluster of buildings that have a dwelling density of R40, that is 40 dwellings are permitted in a 1 hectare area of land. This building has two alternate banks 14A of three units side by side on a first level and one alternate bank of three units on a second level and one alternate bank of three units on a third level.
Building 10C is one building in a cluster of buildings that have a dwelling density of R30, that is 30 dwellings are permitted in a 1 hectare area of land. Building 10D is one building in a cluster of buildings that have a dwelling density of R20, that is 20 dwellings are permitted in a 1 hectare area of land.
Figure 25 is another example of a complex 200 with three buildings of R40 density. Figure 26 shows the make up of each building from the unit types 3, 4, 2 (in the first alternative bank of 3 units) and unit types 8, 3, and 8 (in the second alternative bank of units). It can be seen the areas of units 3 and 4 are combined to form a large room and unit 4 and 3 have a joining doorway and that both of units 8 have joining door ways with unit 3. It can also be seen that the right side unit 8 is a mirror of left side unit 8. Referring to Figure 16 to 18, a three story apartment building 1 10 is shown. In this embodiment the banks are formed of side by side modular units. In this case the widths of bank are the same, but in an alternative embodiment the width need not be the same in each bank.
The ground level is 1 12, the first level is 1 14 and the second level is 1 16. Figure 18 shows the removal of side/end panels used in transport in each back of the ground 1 12, first 1 14 and second 1 16 levels. This allows for larger internal areas or in the case of the units in the ground level side access to the units, such as for car parking spaces. Figure 17 A shows the floor plan of the ground level 1 12 using the types of modular units in Figure 13. Figure 17B shows the floor plan of the first level 1 14 and Figure 17C shows the floor plan of the second level 116.
Figure 19 shows an alternative building comprising a bank of units in a side by side arrangement. In this building, notional unit types are 5, 8 and 9, with 2 of type 5 and type 8 being used, along with the removal of external walls between types 5 and 9, so as to produce a larger area internal to units 5 and 9. The external wall units may be surplus to the units transported. In an embodiment this building can be transported on a single move using a single vehicle (truck / road train). Figure 22 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.
Figure 20 shows an alternative building comprising two banks of units in a side by side arrangement, with the banks being offset by a unit width and with the units end to end. In this building, notional unit types are 1 , 2, 3, 4, 7, and 8, with 1 of type 1 , 2 of type 2, 2 of type 3, 1 of type 4, 3 of type 7 and 1 of type 8 being used, along with the removal of external walls between the 2 type 2 units and the type 4 and 8 units, so as to produce a larger area internal to units 2-2 and 4-8. The external wall units are surplus to the units transported. In an embodiment this building can be transported on a single move using two vehicles (truck / road train). Figure 23 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport.
Figure 21 shows an alternative building comprising three banks of units in a side by side arrangement. In this embodiment two banks are perpendicular and a shorter bank is end to end with one bank and offset from the other bank by a unit width. In this building, notional unit types are 1 , 2, 3, 4, 5, 7, 8 and 9, with 2 of type 1 , 2 of type 2, 3 of type 3, 1 of type 4, 2 of type 5, 1 of type 7, 2 of type 8 and 1 of type 9 being used, along with the removal of external walls between types 1 and 1 , 2 and 2, 3 and 3 and 3 and 4, so as to produce a larger area internal to units 1 -1 2-2, 3-3, 3-4. The external wall units are surplus to the units transported. In an embodiment this building can be transported on a single move using three vehicles (truck / road train). Figure 24 shows an example of how this might be laid out, with the fittings installed for transport and the furnishings, optionally, also packaged in the containers for transport. Figure 27 is another example building of R20 density and is assembled from four alternative banks of three side by side units. The first bank is assembled from unit types 1 , 1 and 0. The next bank is assembled from unit types 4, 3, and 5'. The next bank is assembled from unit types 2, 2, and 0. The final bank is assembled from unit types 5', 5', and 5'.
Figure 28 is another example building of R30 density where each level has a common area 202 and two individual bedrooms adjacent to each staircase.
Figure 29 is a further example building of R30 density similar to Figure 28 with a different floor plan.
The transportability of the units may also be useful not just to construct a build, but also to move the building to a different location, or to break up the building and reuse the modular units on one or more other buildings of different design.
The modular building unit are suitable for transport by road, rail and ship. The dimensions of each unit may be for example 3.3m x 6m, 3.4m x 6m, 3.6m x 7.2m, 3.7m x 7.3m, or otherwise. Modifications may be made to the present invention with the context of that described and shown in the drawings. Such modifications are intended to form part of the invention described in this specification.

Claims

Claims
1 . A building structure formed of one or more elongate clusters, each cluster comprising a plurality of side by side module banks, each module bank formed of end to end modular building units.
2. A building structure according to claim 1 , wherein each of the units has the same dimensions.
3. A building structure according to claim 1 or 2, wherein the modular units are configured such that they can be assembled without structural modification.
4. A building structure according to any of claims 1 to 3, wherein each unit is of a unit type and each unit is configured according to its unit type.
5. A building structure according to claim 4, wherein the configuration comprises one or both of internal wall configuration and external (permitter of the unit) wall configuration.
6. A building structure according to any of claims 1 to 5, wherein the modular units are selected from a selection range of available units and are assembled in a relationship to form functional areas that meet a design requirement.
7. A building structure according to any of claims 1 to 6, wherein the units are stackable for transport and are able to be stacked in the building.
8. A building structure according to any of claims 1 to 7, wherein a room in a cluster is defined by one of:
a portion of a modular unit;
a bank;
a plurality of banks;
a plurality of portions of modular units spaning a plurality of banks.
9. A building structure according to any of claims 1 to 8, wherein there are least three and preferably between six and twenty four banks in each cluster.
10. A building structure according to any of claims 1 to 9, wherein each cluster comprises a plurality of levels, each level comprising a plurality of side by side banks, each bank formed of the end to end units.
1 1 . A building structure according to claim 10, wherein the units of each level are stacked one atop another.
12. A building structure according to claim 10 or 1 1 , wherein a level spanning unit is the height of at least two units.
13. A building structure according to any of claims 1 to 12, wherein areas are provided that span at least one modular building unit.
14. A building structure according to any of claims 1 to 13, wherein an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
15. A building structure according to claim 4, wherein a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor
16. A building structure according to claim 15, wherein the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.
17. A building structure according to claim 15 or 16, wherein an internal portion of the building has a plurality of areas with the same type of use, with an outer portion providing an entrance to the internal portion, the entrance being an area provided for in one type of modular building unit.
18. A building structure according to any of claims 1 to 17, wherein a joining portion of the building joins one bank of connected building units to another bank of building units, such that there is internal, or covered access-way between banks
19. A method of forming a building comprising: determining the usage requirements of the building in terms of types of areas (including rooms) within the building from a plurality of available types;
determining the space requirements of the building in terms of the number of each type of area within the building and size of each type of area, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements;
manufacturing the modular building units according to the determined type and number;
transporting the modular building units to a building site; and
assembling the modular units into the building.
20. A method according to claim 19, wherein the modular building units are stackable for transport and stackable for assembly into the building.
21 . A method according to claim 19 or 20, wherein construction of the building consists of assembly of the modular building units.
22. A method according to any of claims 19 to 21 , wherein the modular building units of each type have one or more of the following predetermined: room size, room position, room orientation, internal walls, entrance/exit, windows, electrical services, plumbing services, and covered areas.
23. A building comprising assembled modular building units, where the units are assembled into one or more groups according to a type of unit used to form one or more types of area in the building, where one or more of the areas may be larger than the size of a building unit by spanning more than one unit, wherein the units have been formed to provide the areas when assembled.
24. A method of forming a building comprising:
determining the usage requirements of the building in terms of types of areas within the building, from a plurality of available types;
determining the space requirements of the building in terms of the number of each type of area within the building and size of each type of area, where each type of area has a plurality of available sizes, the sizes available being smaller than, the same as or larger than a modular building unit;
determining a composition of one or more required types of modular building unit and the number of each type of modular building unit to meet the determined usage requirements and determined space requirements, where the composition is selected form a plurality of stock types;
obtaining the modular building units according to the determined type and number; transporting the modular building units to a building site; and
assembling the modular units into the building.
25. A method according to claim 24, wherein In an embodiment prior to transport one or more of the modular building units are packed into a container form for transport.
26. A method according to claim 24 or 25, wherein the method further comprises specifying internal spaces to conform to a grid dimensioned to the length and width of the modular unit.
27. A method according to any of claims 24 to 26, wherein determining a configuration of the building comprises selecting a type of unit, wherein the unit type determines one or both of internal wall configuration and external (perimeter of the unit) wall configuration.
28. A method according to any of claims 24 to 27, wherein determining the configuration comprises selecting a type of unit, wherein each bank type is determined according to the unit types of its units.
29. A method according to any of claims 24 to 28, wherein determining the configuration comprises selecting units such that there is an area within the building larger than a dimension of the modular units.
30. A method according to any of claims 24 to 29, wherein the modular units are assembled without structural modification.
31 . A method according to any of claims 24 to 30, wherein the determined space requirements comprise determining that the units are to be stacked in the building.
32. A method according to any of claims 24 to 31 , wherein the units are stacked for transport.
33. A method according to any of claims 24 to 32, wherein the determined composition comprises determining a configuration such that a room in a cluster is defined by one of:
a portion of a modular unit;
a bank;
a plurality of banks;
a plurality of portions of modular units spaning a plurality of banks.
34. A method according to any of claims 24 to 33, wherein the determined composition comprises determining a configuration such that there are least three banks in each cluster.
35. A method according to any of claims 24 to 34, wherein the determined composition comprises determining a configuration such that the building is multistorey, with support structures for the multiple stories being provided by structural supports in each modular unit.
36. A method according to any of claims 24 to 35, wherein the determined space requirements comprises determining a configuration such that an area is smaller than or the same size as a modular building unit, with multiples of the area repeating with end to end or side to side modular building units.
37. A method according to any of claims 24 to 36, wherein the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal corridor therein and an entrance doorway to spaces either side of the corridor, where there are a plurality of such modular building units adjacent one another so as to connect the corridor portions to form the corridor.
38. A method according to any of claims 24 to 36, wherein the determined composition comprises determining a configuration such that a modular building unit type has a portion of an internal service corridor therein, where there are a plurality of such modular building units adjacent one another so as to connect the service corridor portions to form the service corridor.
39. A method according to claim 37 or 38, wherein the determined composition comprises determining a configuration such that the corridor is through the centre of the modular building unit and the areas either side of the corridor are mirrored.
40. A building formed by performing the method according to any of claims 24 to 39.
41 . A building structure formed of one or more elongate clusters, each cluster comprising a plurality of end to end module banks, each module bank formed of a plurality of side to side modular building units.
42. A building substantially as hereinbefore described with reference to the accompanying drawings.
43. A method of building a building as hereinbefore described with reference to the accompanying drawings.
PCT/AU2013/000774 2012-07-11 2013-07-11 Modular buildings WO2014008551A1 (en)

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AU2018217199A AU2018217199B2 (en) 2012-07-11 2018-08-13 Modular Buildings

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