Patent EA-004340-B1 (EA)
Title: Improvements to modular buildings and materials used in their construction
Inventor: PARRISH MALCOLM
IPC: E04B7/22
Filed: 2001-04-18
Abstract: 1. A modular building comprising: a foundation floor having secured therein a plurality of anchor elements; a plurality of wall-retaining track elements adapted to engage wall panels of the building, the track elements being securable to the foundation floor so as to define the position of at least the load bearing walls of the building; wall panels locatable with respect to the track elements, each panel including at least one channel or duct formed therein parallel to a longitudinal axis thereof and at least one channel or duct formed therein disposed perpendicularly to and laterally of the longitudinal axis; and a plurality of securing members adapted to pass through and locatable within said channels or ducts, the securing members being anchored at each end thereof so as to maintain the panels in fixed relationship to one another. 2. A modular building as claimed in claim 1, in which the building further comprises a roof structure formed from a plurality of roof panels, each panel including at least one channel or duct formed therein parallel to the longitudinal axis thereof and at least one channel or duct formed therein disposed perpendicularly to and laterally of the longitudinal axis. 3. A modular building as claimed in claim 2, in which the roof panels are secured to a roof beam utilising a plurality of securing members which are adapted to pass through and be locatable within said channels or ducts, the securing members being anchored at each end thereof so as to secure the panels in fixed relationship to one another and the roof beam. 4. A modular building as claimed in any one of the preceding claims, in which the security members comprise rods or cables having high tensile strength characteristics while maintaining flexibility. 5. A modular building as claimed in any one of the preceding claims, in which the securing members include a threaded sleeve element at one or both ends thereof for receiving a securing bolt. 6. A modular building as claimed in any one of the preceding claims, in which one or more of said securing members comprise glass-fibre strands bonded together with the strands in parallel alignment. 7. A modular building as claimed in any one of the preceding claims, in which the securing members are coated with a plastics material such as polypropylene to increase abrasion resistance. 8. A modular building as claimed in any one of the preceding claims, in which the securing members are positioned and tensioned so as to form a net-like structure to resist panel movement. 9. A modular building as claimed in any one of claims 2 to 8, in which the wall or roof panels comprise a composite material utilising silica cenospheres and a resin. 10. A modular building as claimed in claim 9, in which the wall or roof panels have bonded to and across at least part of a surface, a second composite material comprising a plurality of layers, including inner and outer nylon layers, a glass fibre mat layer therebetween and a polymer resin distributed between the nylon layers to bond the layers together. 11. A modular building as claimed in claim 10, in which the thickness of the nylon layers is between 17-21 mum, so that the nylon layers neither tear nor distort during construction. 12. A modular building as claimed in either claim 10 or 11, in which the resin is present in an amount of 30-50% w/w of the second composite material. 13. A modular building as claimed in claim 12, in which the resin is selected from one or more of the following classes of polymeric compounds: polyester; polyurethane, polyacrylic, polyphenolic, polybromophenolic, polyvinylester or epoxy resins, including mixtures thereof. 14. A modular building as claimed in any one of claims 9 to 11, in which there is provided a fire retardant material. 15. A modular building as claimed in claim 14, in which the fire retardant material is included between the nylon layers. 16. A modular building as claimed in claim 14 or claim 15, in which the fire retardant material is selected from aluminium trioxide, glass flakes or a retardant chemical such as polyhalogenated phenols including bromophenols. 17. A modular building as claimed in claim 16, in which aluminium trioxide is provided in an amount 15-50% w/w with respect to the resin. 18. A modular building as claimed in claim 17, in which the aluminium trioxide is present in an amount 30-40% w/w. 19. A modular building as claimed in any one of claims 10 to 18, in which the second composite material includes a glass-tissue layer having a density of 14-30 g/m<2>, to reduce uneven features being introduced to the surface thereof. 20. A modular building as claimed in any one of claims 10 to 19, in which the second composite material includes a colouring agent such as titanium dioxide to improve its appearance. 21. A modular building as claimed in any one of the preceding claims, in which the wall-retaining track elements are bolted to the foundation floor and bonded by means of a mastic sealant. 22. A modular building as claimed in any one of the preceding claims, in which the track elements define a U-shaped cross-section into which the wall element is adapted to sit. 23. A modular building as claimed in any one of the preceding claims, in which the track elements include a raised rail portion adapted to engage a corresponding groove in an edge region of the panels. 24. A modular building as claimed in any one of the preceding claims, in which the anchor elements are provided in the foundation floor for connection to securing members disposed within the channels or ducts formed parallel to the longitudinal axis of the panels. 25.A modular building as claimed in any one of the preceding claims, in which the wall panels additionally comprise one or more ducts or channels to receive electric wires or a plumbing system. 26. A modular building as claimed in any one of the preceding claims, in which the wall panels additionally comprise apertures to receive floor and window cartridge units. 27. A modular building as claimed in any one of the preceding claims, in which sealant is provided between adjacent wall panels to give increased strength and water resistance. 28. A method of constructing a building including the steps of: preparing a ground area on which the building is to stand to receive a foundation floor; forming a foundation floor having secured therein a plurality of anchor elements; securing wall-retaining members to the foundation floor over said anchor elements, to define the location of load bearing walls; attaching elongate security members to the anchor elements; locating wall panels, having one or more security member receiving channels, with respect to the wall-retaining members; securing wall panels by threading the flexible securing members through the wall panels; tensioning said securing members; and locking the securing members to attenuate movement. 29. A method of constructing a building as claimed in claim 28, in which the method includes dispensing mastic sealant between the wall-retaining members and the foundation floor. 30. A modular building substantially as herein described with reference to and as shown in the accompanying drawings. 31. A composite material wall or roof panel substantially as herein described with reference to and as shown in the accompanying drawings. 32. A method of construction a building substantially as herein described with reference to the accompanying drawings.