MODULAR BUILDINGS

Abstract: Modules for construction of modular buildings comprise a substantially rectangular box frame and are adapted to interconnect with other modules located horizontally and/or vertically adjacent. The modules are prefabricated and assembled or interconnected on site, prefabrication being assisted by an apparatus having rotatable clamping means for rotating the module frame during construction to provide a desired working height.

Description: "Modular Buildings" This invention relates to modular buildings and to modules for use in such buildings. Buildings are traditionally built in situ from relatively small components. The disadvantages arising from this are well known, and include low speed of construction and problems caused by bad weather. It is also well known to use portable prefabricated buildings, but these generally have limitations of size and are not well suited to combining together to make relatively large accommodation units or a single building of good aesthetic appearance. Buildings of traditional construction also present problems when repair is required following, for example, storm or fire damage. Since the building is essentially continuously interlinked, removal of damaged parts may seriously weaken other parts not originally damaged. An object of the present invention is to overcome or mitigate these problems. Accordingly, the invention provides a building comprising a plurality of box-shaped modules juxtaposed horizontally and/or vertically; each module comprising a base frame of peripheral side and end members arranged in a rectangle, a top frame of peripheral side and end members arranged in rectangle, and pillar members interconnecting the corners of the base frame and the top frame; the pillar members of vertically juxtaposed modules being in load-bearing connection, and the pillar members of ground-level modules bearing on foundations, whereby the load of the building is carried by the pillar members. Preferably, the pillar members are open at top and bottom, and the building includes elongate tension members passing through the pillar members and exerting a downward force on the corners of the modules. Preferably, the tension members bear on locating plates provided with projections locating within pillar members of adjacent modules. Locating plates may be provided having one to four projections on one face, or one to four projections on each face, whereby any combination of module junctions may be accommodated. The building may be provided with external non-lσad-bearing columns arranged at intervals such that vertical joins between modules are masked. Alternatively, exterior cladding covering the joins may be used for this purpose. Preferably also, the modules are prefabricated with floors and ceilings, and some of the modules with external cladding and glazing, before installation. Modules may also be prefabricated as stairways, fire lobbies, toilets, kitchens and the like. From another aspect, the invention provides a building module comprising a base frame of peripheral side and end members arranged in a rectangle, a top frame of peripheral side and end members arranged in a rectangle, and pillar members interconnecting the corners of the base frame and the top frame; the pillar members being adapted to carry the weight of the module and being adapted to support loads from superimposed pillar members of another module when positioned vertically above. Preferably, said pillar members and frames are of rectangular steel tubing and are welded together to form the module. Preferably also, the pillar members are open at top and bottom for through passage, in use, of tensioning members. A further aspect of the invention resides in an apparatus for use in making building modules and similar structures, the apparatus comprising a pair of spaced-apart frames, each of which is mounted for rotation about a common horizontal axis, each frame being provided with means for clamping a pair of pillar members parallel to each other in a vertical plane, whereby horizontal beams may be welded between pillar members carried by the frames which may be rotated to provide a desired working height. Preferably, the apparatus includes means for rotatably driving at least one of the frames. Preferably also, means are provided, such as in the form of a pneumatic, mechanical or hydraulic ram, to lock the frames in a desired rotational position. Preferably also, lifting means are provided to position further material against said beams for fastening to the module. An embodiment of the invention will now be described, by way of example only, with reference to the drawings, in which:- Fig. 1 is an end elevation of a building constructed in accordance with the present invention; Fig. 2 is a front elevation of the building of Fig. 1; Fig. 3 is a sectional plan view of an upper floor of the building, on the line 3-3 of Fig. 2; Fig. 4 is a vertical section of the building on the line 4-4 of Fig. 3; Fig. 5 is a plan view of one module used in constructing the building; Fig. 6 is an enlarged sectional plan showing details of an external corner of the building; Fig. 7 is a sectional side view illustrating a means of connection within the structure; Fig. 8 is a side view of an apparatus for use in manufacture of building modules; and Fig. 9 is an end view of the apparatus of Fig. 8. Referring to Figs. 1 to 4, a building 10 has an externally conventional appearance with walls 12 formed by cladding panels 14, glazed panels 16 and columns 18, and a pitched roof 20. The load-bearing structure of the building 10 is formed by a plurality of cellular modules juxtaposed horizontally and stacked vertically. The upper floor seen in Fig. 3, for example, comprises a staircase and fire lobby module 22, a toilet and kitchen module 24, and an open plan office area made up by modules 26-36. As shown in Fig. 5, each module includes corner pillars 38, the lower ends of which are interconnected by floor level beams 40 and the upper ends by similar ceiling-level beams 42 (not seen in Fig. 5). The members 38, 40 and 42 are rectangular steel sections 120 mm x 120 mm. The beams 40, 42 are interconnected by vertical 100 x 50 mm steel sections 44 on 600 mm centres in those areas destined to form part of an external wall. Similar vertical members of smaller cross-sectional dimension may be provided as a basis for internal partition walls. All of the foregoing are welded to form a strong cage-like structure, suitably with overall dimensions of 5594 mm x 2794 mm x 3355 mm high. A significant feature of the present invention is that all building loads are carried via the pillars 38. The pillars 38 in the upper floor are mounted on and secured to those immediately below as will be described. Those of the bottom floor are supported by concrete pad foundations 46 (Fig. 4). It will be appreciated that, to construct the building 10, the site is levelled and the pad foundations constructed as required in a grid. The various modules are then craned into position and locked together. The modules can be wholly or partially finished in the factory before being brought to site. Fig. 6 shows an enlarged detail of a corner joint, with typical cladding and filling materials. The external wall of each module comprises an external cladding sheet 48 for example of 6 mm Resoplan, a layer 50 of Corovin building paper, 100 mm of rockwool insulation 52, and two thicknesses of plasterboard 54 on softwood battens 56. The corner is closed by a column 18 of part-cylindrical form comprising stainless steel sheet 60 with an internal coating 62 of sprayed foam insulation 30 mm thick. Silicon sealant 64 is gunned into the gaps between the cladding 48 and the column 18. As best seen in Fig. 3, the columns 18 cover the vertical joins between abutting modules, and are also provided as dummy columns at the midpoints of long module sides. Providing columns at a uniform spacing allows maximum flexibility of module layout, and a good external appearance. The columns 18 also provide a convenient means of concealing rain-water pipes, as at 58 in Fig. 4. Cylindrical columns 66 (Fig. 3) are provided within the building to shroud exposed butting corner pillars 38, and again dummies such as 68 may be provided for uniformity of appearance. It is realised in the invention that these columns may comprise any appropriate cross-section and by no means need to be part-cylindrical. Furthermore, the cladding and filling materials may be varied, as required, and may be designed to negate the need for columns altogether. The method of interconnecting the modules is shown in Fig. 7. An apertured base plate 70 is bolted to the foundation pad (not shown) . Two short lengths of pipe or the like 72 are welded to the upper face of base plate 70 to locate corner pillars 38 of adjacent ground-floor modules. Alternatively, the plate may be a casting having suitable projections for locating corner pillars 38. A threaded tensioning rod 74 for each pillar is fastened in the base plate and passes through the pillar. A connector plate 76 with upper and lower locating pipes 78 is positioned over the pillars 38 and tensioning rods 74, and the assembly pulled tight by nuts such as 80. Thereafter further tensioning bars 82 may be added via splicing couplers 84, the first floor modules lowered into position, and the procedure repeated. In this manner, the modules can be accurately located in all axes and the whole assembly drawn together, with all building loads being transmitted via the corner pillars to the foundation. The base plates 70 may be adapted to fit one column 38, as in the case of the corner of a building, or two adjacent columns as in the case of an external wall of a building, or four adjacent columns at the corner of four interconnecting modules. Similarly, the connector plates 76 may be adapted on one or each side to fit one, two or four columns. The system of construction thus described has the advantage that individual modules can be removed and replaced, to effect repairs or remodelling, without substantial effect on the safety or stability of other parts of the building. The modules used in the present invention may conveniently be manufactured using the apparatus of Figs. 8 and 9. Spaced frames 100 mount stub shafts 102 which carry cruciform assemblies 104 one of which can be driven in rotation by a motor (not shown) via gearing 106. Each assembly 104 provides two fixed legs 108 and two movable legs 110 which can be clamped in position. In use, four corner pillars 38 can be clamped in the two assemblies 104 and held at a suitable orientation to allow the upper and lower beams 42 and 40 to be welded in place. The work can be rotated so that each weld is made at a height convenient to the operator. Rams 112 are provided for locking the assemblies in position while work takes place. Once the basic skeleton has been fabricated, other members may be welded in position with the module in the apparatus. A pair of parallel bars 114 vertically movable by jacks 116 is provided beneath the working position. This may be a hydraulic jacked trolley or similar apparatus. These are particularly useful if it is desired to weld sheet steel to the skeleton, as sheets can be clamped in position by the jacks 116 while welding is effected. During construction, the open ends of the horizontal and vertical frame members are aligned adjacent to a similar member and may be seal welded. The ends of the frame members which are to remain open are internally sprayed with an anti-rust composition. Flooring may be achieved by a variety of simple methods. For example, as in the case of walls, panels may be fully constructed and then bolted, or otherwise mounted, as a single unit to the frame. Extra horizontal frame members may also be welded on the floor side of the frame to increase the strength of the floor. Also panel members may be constructed not only from steel, but any suitable material including hard and soft woods, and composites. The floor panels may then be covered by a concrete skin and/or tiled, carpeted and so on. Where concrete is required for tiling or sound temperature insulation, only a concrete skin of approximately 0.5 to 0.75 inch thickness is necessary, enabling a significant weight and cost reduction. The apparatus of Fig. 8 and 9 is also useful in the production of other items with an external framework of welded beams and columns, such as transport containers to ISO requirements. Modifications and improvements may be incorporated without departing from the scope of the invention.

Claims: CLAIMS 1. A building comprising a plurality of box-shaped modules juxtaposed horizontally and/or vertically; each module comprising a base frame of peripheral side and end members arranged in a rectangle, a top frame of peripheral side and end members arranged in rectangle, and pillar members interconnecting the corners of the base frame and the top frame; the pillar members of vertically juxtaposed modules being in load-bearing connection, and the pillar members of ground-level modules bearing on foundations, whereby the load of the building is carried by the pillar members. 2. A building as claimed in Claim 1, wherein the pillar members are open at top and bottom, and the building includes elongate tension members passing through the pillar members and exerting a downward force on the corners of the modules. 3. A building as claimed in Claim 1 or Claim 2, wherein the tension members bear on locating plates provided with projections locating within pillar members of adjacent modules. 4. A building as claimed in any one of the preceding Claims also including non-load-bearing columns arranged at intervals such that vertical joins between modules are masked. 5. A building as claimed in any one of the preceding claims wherein vertical joins between modules are masked by overσladding. 6. A building as claimed in any one of the preceding Claims, wherein the modules are prefabricated with floors and ceilings, and some of the modules with external cladding and glazing, before installation. 7. A building module comprising a base frame of peripheral side and end members arranged in a rectangle, a top frame of peripheral side and end members arranged in a rectangle, and pillar members interconnecting the corners of the base frame and the top frame; the pillar members being adapted to carry the weight of the module and being adapted to support loads from superimposed pillar members of another module when positioned vertically above. 8. A building module as claimed in Claim 7, wherein pillar members and frames are of rectangular steel tubing and are welded together to form the module. 9. A building module as claimed in Claim 7 or Claim 8, wherein the pillar members are open at top and bottom for through passage, in use, of tensioning members. 10. An apparatus for use in making building modules and similar structures, the apparatus comprising a pair of spaσed-apart frames, each of which is mounted for rotation about a common horizontal axis, each frame being provided with means for clamping a pair of pillar members parallel to each other in a vertical plane, »whereby horizontal beams may be welded between pillar members carried by the frames which may be rotated to provide a desired working height. 11. An apparatus as claimed in Claim 10 also including means for rotatably driving at least one of the frames. 12. An apparatus as claimed in Claim 10 or Claim 11 also including means to lock the frames in a desired rotational position. 13. An apparatus as claimed in Claims 10-12, also including lifting means to position further material against said beams for fastening to the module.

Inventors: ADAMS JAMES, FIONDA RALPH, FORREST BRIAN, LYNCH JOHN, MARSHALL RICHARD, STEWART ALLAN, TEDESCO DOMENIC, ADAMS, JAMES, FIONDA, RALPH, FORREST, BRIAN, LYNCH, JOHN, MARSHALL, RICHARD, STEWART, ALLAN, TEDESCO, DOMENIC
Applicants: ERGOTRAK BUILDING SYSTEMS LTD, ERGOTRAK BUILDING SYSTEMS LIMITED
Application year: 1991
Main classification: E04B1
IPC codes: E04B1