Source: http://www.allindianpatents.com/patents/235267-building-modules
Timestamp: 2018-01-22 08:36:00
Document Index: 235537035

Matched Legal Cases: ['art 82', 'art 82', 'art 82', 'art 82', 'art 82', 'art 82', 'ART 10']

Indian Patents. 235267:"BUILDING MODULES"
"BUILDING MODULES"
The present invention provides a building module (10) having an exterior shape generally of a cuboid having side (12), end (11), top (13) and bottom (14) faces, and fabricated from metal, the module (10) being hollow and defining a space of a size suitable for occupation by a person, the module (10) being provided with fastening elements (21, 69) to allow the module (10) to be fastened to another adjacent module, wherein the module (10) has an overall exterior width greater than 2700 mm and has a first set of fastening elements (21, 69A, 69B, 69C, 69D) in the region of a first end of die top (13) of the module (10) and a second set of fastening elements (21, 69A, 69B, 69C, 69D) in the region of a second end of the top of the module (10), the fastening elements of each set having two fastening elements (e.g. 21, 69C) spaced apart from one another at a centre-to-centre spacing (D) of about 2260 mm, said fastening elements (21, 69) allowing engagement by standard load handling equipment for handling freight containers.
This invention relates to a building module/ to
buildings made from such modules and to the construction of
buildings using such modules.
There have been many prior proposals for constructing
buildings from prefabricated units. In some proposals,
panels are prefabricated and transported to a site for
assembly into a building. The transport of the panels is '
reasonably straightforward but the assembly on site
involves a considerable amount of labour. In other
proposals, an entire building is prefabricated and
transported, often with some difficulty. Another option is
to make a building from several prefabricated threedimensional
modules and assemble the modules on site, but
in that case both transport and assembly tend to be
time-consuming and expensive. In an attempt to alleviate
that problem it has been proposed to use a conventional
freight container as a building module. For example,
US 4599829 shows a building system formed of freight
containers. The containers are each of the standard
dimensions of a freight container and have corner castings
at each of their corners. Those corner castings are
provided at the standard spacings (a centre-to-centre
spacing of about 2259 mm) so that the container can be
handled in the same way as a conventional freight
improved form of building module.
improved form of building made from such modules.
It is a still further object of the invention to
provide an improved method of constructing a building using
such modules.
According to a first particular aspect of the
invention there is provided a building module having an
exterior shape generally of a cuboid having side, end, top
and bottom faces, and fabricated from metal, the module
being hollow and defining a space of a size suitable for
occupation by a person, the module including fastening
elements to allow the module to be fastened to another
adjacent module to allow for engagement by standard load
handling equipment for handling freight containers, wherein
the module has an overall exterior width greater than
2700 mm and includes a first set of fastening elements in
the region of a first end of the top of the module and a
second set of fastening elements in the region of a second
end of the top of the module, the fastening elements of
each set including two fastening elements spaced apart from
one another at a centre-to-centre spacing of about 2260 mm.
Thus the invention provides a module which can be of a
size that enables it to be transported but which is able to
be fastened to other modules on site to form a larger
building in a quick and simple manner. Furthermore by
providing fastening elements at a centre-to-centre spacing
of about 2260 mm, handling and transport of the module is
greatly facilitated since the module can be handled and
transported by the same equipment as handles and transports
standard freight containers.
Preferably the two fastening elements are
symmetrically positioned on opposite sides of a central
vertical plane of the module. In that case, they will both
be inboard of the sides of the module and it is generally
preferred that the set of fastening elements further
include third and fourth elements at the opposite side
edges of the top of the module. It is also preferred that
each of the first and second sets of fastening elements
comprises more than two fastening elements at locations
spaced across the top of the module each fastening element
being spaced from another fastening element at a centre-tocentre
spacing of about 2260 mm.
The first and second sets of fastening elements will
usually be provided at the opposite ends of the module but
that will not necessarily be the case and they may be
provided inboard of the ends so as to be spaced apart from
one another longitudinally by a standard distance. Thus
reference is also made to the sets of fastening elements
being in the regions of the ends of the module.
In addition to providing first and second sets of
fastening elements in the regions of the ends of the top of
the module, third and fourth sets of fastening elements are
preferably provided in the regions of the ends of the
bottom of the module. The third and fourth sets of
fastening elements may be arranged in the same way as
described above in respect of the first and second sets of
Preferably there are respective elongate members in
the region of each of the eight edges of the cuboid and a
plurality of metal panels secured to at least some of the
elongate members. The elongate members are preferably of
an open or hollow section, for example of hot or cold
rolled or folded section, prefabricated section or
rectangular hollow section. The elongate members and panels
preferably together define a monocoque structure. The
elongate members and panels are preferably made of steel.
Such a construction enables a module as large as can
readily be transported by road to be fabricated with
sufficient strength that it is self supporting.
Furthermore, when in use the module is fastened to other
modules that can enhance their strengths so that a
structurally strong building can be formed by fastening the
modules together. Such a structure can have sufficient
strength not only to support itself even as a multi-storey
structure (consisting for example of more than 10 or 20
storeys) but also to support other structural elements such
as bridging elements or cantilevered elements without
In most cases, it will be preferred that there are
metal panels secured on all of the side and end faces of
the cuboid, and preferably also on the top and bottom faces
of the cuboid. At least some of the metal panels may be
corrugated. Such corrugations add to the strength and
stiffness of the panel. One or more of the metal panels
may, whether or not they are corrugated, be of composite
construction and may for example include insulating
material and/or an inner lining.
Since the module is to form part of a building, it is
preferable that it is fabricated with appropriate openings
formed therein. The openings may be covered over for the
purpose of transporting modules from a factory where they
are fabricated to a site where they are to be used in a
building; such temporarily closed openings in the module
are hereby defined as "open" for the purpose of this
specification. For example, one side face or each side
face of the module may be partly closed by a panel and be
partly open; similarly, one end face or each end face of
the module may be partly closed by a panel and be partly
open. The partly open face, or one of the partly open
faces, may extend from a region at the bottom of the face
to a region at the top of the face; that may provide an
access route, for example a doorway, into the module for a
person; of course, the doorway need not extend to the very
top or the very bottom of the face. The partly open face,
or one of the partly open faces, may extend upwardly from a
region partway up the face. That may for example provide a
window opening. One or more openings may also be provided
in the top or bottom faces of the module, tor example to
accommodate a staircase, lift or services within the
The module may be fabricated as a completely empty
shell and may remain in that state until after assembly
into a building. More commonly, however, it will be
preferable to carry out a degree of fitting out either in
the factory or on site but prior to assembly into a
building. For example, insulation may be added to walls,
floors and ceilings, a plywood lining may be provided over
the insulation, doors, windows and balconies may be added.
Further examples may be electrical, power and lighting
cabling systems, heating and plumbing systems,
telecommunications systems and other media communications
systems. A cladding may also be added to one or more faces
of the module. That cladding may be brickwork or some
other cladding such as wood panelling/ metal sheet
cladding. The cladding may be tile hung or in the form of
a curtain wall. The cladding may provide a glass facade.
Ties or other systems for holding the cladding in place may
be provided. The ties may be retained in slots in a panel
forming a face of the module; alternatively cladding
fixings may be fixed to castings or plates of a frame of
the module. A pod containing selected fittings may be
installed in the module. For example there may be a
kitchen pod containing kitchen fittings or a bathroom pod
containing bathroom fittings. Such a pod may occupy a
minor part only of the interior volume of the module.
The ability of the module to be fastened to adjacent
modules represents a key feature of the invention.
Preferably the fastening elements of the module are
suitable for fastening the module to an adjacent module
placed alongside and/or to an adjacent module placed endto-
end and/or to an adjacent module placed above or below.
Thus modules may be fastened together in arrays of one, two
or three dimensions. Most commonly the modules are
fastened together in a two- or three-dimensional array with
a plurality of storeys, each storey comprising a plurality
of modules placed alongside one another.
At least some of the fastening elements are preferably
provided in the region of the eight corners of the module.
As will be clear from the description below, those
fastening elements may be the only fastening elements, but
there may also be other fastening elements, for example
partway along the top and/or bottom side edges of the
module. Such a fastening element may transfer a building
load to a foundation and/or provide a connection to an
In accordance with an especially preferred feature of
the invention, at least some of the fastening elements are
defined by hollow blocks with openings through which
connector elements can be inserted. The fastening elements
are preferably provided with openings in their top, side
and end faces or bottom, side and end faces. The fastening
elements are preferably welded to the elongate members.
The fastening elements may be in the same general form as
corner castings of freight containers and may be in
accordance with ISO/TC-104-1161. Some or all of the
fastening elements may, however, be of a design which
differs from ISO/TC-104-1161 in order to meet the special
requirements of a building module of the present invention.
For example longer fastening elements may be used in some
cases and where fastening elements are provided away from
the corners of the module they may have a top or bottom
opening and only one further aperture. Furthermore
openings in the fastening elements may vary from the
standard and, for example, a fastening element on the top
of the module may have an opening in its end face of the
kind provided in a standard container for the front face of
a fastening element at the bottom of the container. That
facilitates handling and transport of the module between a
factory where it is fabricated and its final destination.
By using the same fastening elements for transporting and
handling the module as are used for securing one module to
another an especially advantageous, economical and time
saving system is provided.
The connector elements and hollow blocks are
preferably arranged such that after a connector element has
been inserted into an opening in a hollow block it can be
fastened in the opening. Thus the connector element
preferably not only locates the module relative to the
connector element but also fastens it to the connector
element. Various fastening arrangements, including manual
and automatic arrangements, may be employed, depending upon
the particular circumstances. The connector elements and
hollow blocks may be arranged such that after a connector
element has been inserted into an opening in a hollow block
it can be fastened in the opening by a fastener entering
the hollow block through another opening and engaging the
connector element. In that manner a very strong and
reliable fastening of the connector element to the block
can be obtained. The connector elements may be fastened in
the hollow blocks by fasteners screw threadedly engaging
the connector elements in the hollow blocks.
To connect one module to another which may be
immediately above or below it, or alongside it, the
connector elements preferably include a connector element
that has a first part for insertion into an opening in one
fastening element of one module and a second part for
insertion into an opening in another fastening element of
another module. In other cases it is desirable to connect
four modules together, for example to connect two modules
that are alongside one another to two further modules
immediately above them to form what may be regarded as a
two-dimensional array of modules. For that purpose the
fastening element of one module, a second part for
another module, a third part for insertion into an opening
in yet another fastening element of yet another module and
a fourth part for insertion into an opening in a still
further fastening element of a still further module. In
further cases it is desirable to connect further modules in
end-to-end relationship with some of the modules to form
what may be regarded as a three-dimensional array of
modules. For that purpose the connector elements
preferably include a connector element having the first to
fourth parts referred to above, but also fifth, sixth,
seventh and eighth parts for insertion into openings in
fastening elements of other modules.
Gaskets are preferably located between a connector
element and a hollow block into which the connector element
is inserted. Such a gasket can accommodate expansion or
contraction of modules, relieve stresses and isolate
Where reference is made herein to a corner casting, it
should be understood that the term "casting" is employed
because that is the standard terminology. Whilst such
elements are usually formed by casting, it is not an
essential feature of the invention that they are formed by
casting. They may for example be fabricated from sheet
steel. Furthermore where reference is made to a corner
casting or a block it should be understood that, whilst
such an element will usually be formed separately and
subsequently fixed to the rest of the module for example by
welding, it is within the scope of the invention for the
corner casting or block to be formed as an integral part of
the rest of the structure of the module.
Standard load handling apparatus is designed to engage
corner castings having a centre-to-centre spacing of about
2260 mm (the precise spacing is usually intended to be
2259 mm in accordance with the Standards and is therefore
referred to here as "about 2260 mm"). In accordance with
another aspect of the invention the overall exterior width
of the module may be in the range of 2350 mm to 2500 mm,
allowing for corner castings at the corners of the module
to have a centre-to-centre spacing of about 2260 mm. In
most applications, however, it will be desirable for the
module to have a greater overall width. In that case it
may be desirable to provide one or more additional
fastening elements along each top and bottom end edge of
the module; a single additional fastening element may be
adequate and may be spaced at a centre-to-centre spacing of
about 2260 mm from a fastening element at a corner of the
module. That fastening element may be off centre or may be
equispaced from corners at opposite sides of the module.
Alternatively and as described above, a pair of additional
fastening elements may be provided symmetrically on either
side of a central plane of the module along a top end edge
of the module at a centre-to-centre spacing of about
2260 mm. It is also desirable to provide a pair of
additional fastening elements symmetrically on either side
of a central plane of the module along a bottom end edge of
the module at a centre-to-centre spacing of about 2260 mm.
The additional fastening elements can then be used, for
example, to secure a module on a road trailer/chassis or a
transport chassis provided at a handling terminal. It is
possible for a module to be less than 2400 mm in width; in
that case it may be advantageous for modules to be
connected together side-by-side for transport. For example
two modules, each of about 1250 mm in width could be
Especially in the case of relatively long modules, it
may also be advantageous to place fastening elements
partway along top and bottom side edges of the module.
That may facilitate handling and transport and may also be
used for connections to foundations or adjacent modules, as
Where the overall width of the module exceeds the
range of 2350 mm to 2500 mm given above, it is preferably
up to 1.5 or 2 times that width, and therefore preferably
up to 4900 mm. If a module is not more than 3660 mm (1.5
times standard width) that has the advantage that two
modules placed side-by-side then occupy the space that
would typically be allocated to three freight containers
placed side-by-side, namely up to about 7400 mm total
width. For modules greater than 3660 mm wide and up to
4900 mm wide, the space used for one module would be the
space typically allocated for two standard containers
placed side-by-side. That can for example facilitate
transport of the modules by a container ship or other
Other dimensions of the module may also be matched to
those of a freight container. Such containers are commonly
of lengths of 10 ft (2991 mm), 20 ft (6058 mm), 30 ft
(9125 mm), 40 ft (12192 mm), 45 ft (13716 mm) or,
especially in USA and Canada, up to 53 ft (17154 mm). The
overall length of the module is most likely to be in the
range of 6000 mm to 6100 mm, in the range of 12100 mm to
12300 mm or in the range of 13600 mm to 13800 mm, those
being the most commonly used dimensions for freight
For lengths of module greater than 40 ft (12192 mm),
fastening elements are preferably provided at the same
positions longitudinally as on a standard 40 ft (12192 mm)
container to allow lifting and vessel stowage using
equipment of standard dimensions and with standard vessel
stowage arrangements.
Preferably the exterior of the module is fitted with a
plurality of additional fastening elements for interfacing
with an external wall cladding system and/or a roofing
system. In that way the addition of a wall cladding system
or a roofing system may be greatly facilitated. The
additional fastening elements are preferably secured to one
or more of the elongate members. Such additional fastening
elements can be of the same or different design from the
fastening elements that are, or act as, the standard
castings of a freight container. The fastening elements
may also be used for fixing other structural elements such
as balconies, corridors, stairs or bridging elements to the
The description above has been provided principally
with reference to a building module according to the first
particular aspect of the invention. It should be
understood that the many features described above can also
be incorporated advantageously in a module which differs in
some respect from the module of the first particular aspect
of the invention, for example because it has an overall
exterior width of less than 2700 mm. According to a broad
aspect of the invention there is provided a building module
having an exterior shape generally of a cuboid having side,
end, top and bottom faces, and fabricated from metal, the
module being hollow and defining a space of a size suitable
for occupation by a person, the module including fastening
Such a module may further incorporate any of the
features described above of the module according to the
first particular aspect of the invention.
An important aspect of the invention is that the
modules are not usually employed individually but rather
are fastened together as a multiplicity (a "multiplicity"
as used herein refers to three or more) of modules. Thus
the present invention further provides a multiplicity of
modules for fastening together to form part or all of a
building, each module having an exterior shape generally of
a cuboid having side, end, top and bottom faces, being
hollow and defining a space suitable for occupation by a
The modules may all be of the same dimensions but it
may also be the case that their dimensions vary, especially
in terms of their widths and lengths. Conveniently, at
least the majority of the modules have a width which is
approximately one, two or three times a given unit width.
For example the given unit width may be 1220 mm, some
modules may have a width of about 2440 mm and some modules
may have a width of about 3660 mm and some may even have a
width of about 4880 mm. Similarly, at least the majority
of the modules may have a length which is approximately
one, two, three, four or five times a given unit length.
In particular applications it may be desirable for a module
to be of exceptionally short length and there may therefore
be at least one module which has a length which is less
than one fifth of the length of the longest module. The
short module may be transported with another longer module
and result in a combined length that matches a standard
length and therefore facilitates transport.
At least the majority of the modules may be of
approximately the same height. That may be advantageous in
the case of a group of modules for use in the same
building. The preferred height of module may vary from one
design of building to another, or from one part of a
building to another. A module may also be provided in a
flat pack form and sides of the module erected on site.
Preferably there is further provided a foundation
interface having a lower face for resting on foundations
and an upper face carrying connector elements for
engagement with fastening elements on modules to fasten the
modules to the foundation interface. The lower face of the
foundation interface can be connected to the foundations in
a conventional manner and is then able to provide the
special fastening arrangement for engaging fastening
elements on the modules. The connector elements can engage
the fastening elements in the same manner as described
above in respect of the connector elements connecting two
modules together. The foundation interface may be in the
form of one or more rectangular rings, opposite ends of a
module resting on opposite sides of a ring. An alternative
arrangement is to fix the connector elements in appropriate
locations directly onto conventional foundations.
Similarly an inter storey interface may be provided
for placing between storeys of modules, the inter storey
interface having a lower face carrying connector elements
for engagement with fastening elements on modules in a
storey immediately below the interface and having an upper
face carrying connector elements for engagement with
fastening elements on modules in a storey immediately above
the interface. Again, the connector elements can engage
the fastening elements of the modules in the same manner as
described above in respect of the connector elements
connecting two modules together. The inter storey
interface may also be in the form of one or more
rectangular rings.
Each module of the multiplicity of modules may include
any of the features referred to above.
building including a multiplicity of modules as defined
above, the modules being fastened together to form part or
all of a building with aligned openings in adjacent walls
of adjacent modules to allow a person to move from one
The modules of the building may be fastened together
in side-by-side relationship and/or in end-to-end
relationship and/or there may be a plurality of storeys of
modules, the modules in one storey being fastened to
modules in an adjacent upper and/or lower storey.
The connected modules may provide the majority or all
of the structural strength of the building, other
structural elements such as cladding, roofing, balconies
and stairwells being supported from the modules. For
example, a roofed space and bridging corridors may be
provided between two spaced apart groups of modules and
supported by the modules. Another possibility is to
connect a module that is without sides, ends or a top to
adjacent modules to form a floor above which there may be
open or covered space.
The invention still further provides a method of
constructing a building at a site, the method comprising
fabricating a plurality of modules at a location
remote from the site, each module being generally in the
shape of a cuboid and including fastening elements/
fastening together the fastening elements of modules
to connect the modules together with aligned openings in
adjacent walls of adjacent modules to allow a person to
move from one module to another.
Preferably the fabricated modules are engaged by their
fastening elements to secure them during transport. That
facilitates the securing of the modules while they are
being transported. Similarly, it is preferred that the
modules are engaged by their fastening elements to move
them into their final positions at the site.
The building that is constructed by the method of the
invention is preferably a building comprising a
multiplicity of modules and being as defined above.
By way of example, certain embodiments of the
Figure 1 is a perspective view of a building module,
Figure 2 is a cut-away view of a part of the module
of Figure 1 showing the wall construction,
Figure 3 is a cut-away view of a part of the module
of Figure 1 showing the floor construction,
Figure 4 is a perspective view of a fourth building
module being secured to three others during
Figure 5 is a sectional plan view of one storey of a
building formed from eleven modules in each
Figure 6A is a perspective view of a first particular
exemplary form of module,
Figure 6B is a perspective view of a second particular
Figure 6C is a perspective view of a third particular
Figure 6D is a perspective view of a fourth particular
Figure 7 is a perspective view of an open span
construction formed from two modules,
Figure 8A is a fully exploded perspective view of a
fastener assembly for fastening four
containers together at adjacent corners,
Figure 8B is a partly exploded perspective view of the
fastener assembly of Figure 8A,
Figure 8C is a perspective view of the fastener
assembly of Figure 8A,
Figure 9A is an end view of the fastener assembly of
Figures 8A to 8C with fastener bolts
Figure 9B is a side sectional view of the fastener
assembly of Figure 9A with fastener bolts
Figure 9C is a plan view of a connector element for
use in the fastener assembly of Figure 9A,
Figure 9D is an end view of a lock down plate for use
in the fastener assembly of Figure 9A,
Figure 9E is a side view of the lock down plate shown
in Figure 9D,
Figure 9F is a side sectional view of the complete
fastener assembly of Figure 9A,
Figure 9G is a fully exploded perspective view of the
complete fastener assembly of Figure 9A,
Figure 9H is a perspective view of the connector
element shown in Figure 9C,
Figure 9J is a perspective view of a first modified
form of the connector element of Figure 9H,
Figure 9K is a perspective view of a second modified
Figure 10 is a perspective view of a module including
brickwork on an end face of the module,
Figure 11 is a perspective view of a module with its
top not shown and showing certain fittings
in the module,
Figure 12A is a perspective view of a module with
various dimensions marked,
Figure 12B is a perspective view of a modified form of
the module of Figure 12A with other
dimensions marked,
Figure 12C is a perspective view of the module of
Figure 12B, showing how it may be engaged
for handling and lock down,
Figure 13 is a perspective view showing a module being
lowered onto a foundation interface ring,
Figure 14 is a perspective view of a module with a
much shorter module fastened thereto in endto-
Figure 15 is a sectional view through a roof, floor
and side of a pair of modules stacked on top
Figure 16A is a sectional view of an external wall of
Figure 16B is a sectional view of adjoining internal
walls of adjacent modules,
Figure 17A is a perspective view of a large module,
Figure 17B is a perspective view of a building formed
from two of the modules of Figure 17A
together with a smaller module,
Figure 18A is a plan view of a fitted out ground floor
of the building of Figure 17B,
Figure 18B is a plan view of a fitted out first floor
Figure 18C is a first elevation of a fitted out
building of the kind shown in Figures 18A
and 18B, and
Figure 18D is a second elevation of the fitted out
Fig.l shows a typical module in accordance with the
invention. The module 10 is in the shape of a cuboid
having opposite end faces 11 (only one of which is visible
in Fig. 1), opposite side faces 12 (only one of which is
visible in Fig. 1), a top face 13 and a bottom face 14. In
the case of the example shown in Fig. 1, the module has an
opening 15 in its side face extending from a region at the
bottom of the face to a region at the top of the face, and
an opening 16 in its end face extending upwardly from a
region partway up the face. Panels 15A and 16A are
provided to close the openings 15 and 16 respectively prior
to final installation of the module. The opening 15 is of
sufficient height to allow a person to walk through
unobstructed and the opening 16 is of a suitable size and
position to provide a window. Similar openings are
provided in the other side and end faces not visible in
The module 10 has a steel monocoque shell structure
formed by four horizontal side rails 17, four horizontal
end rails 18 and four vertical posts 19, all of open
section, and by corrugated steel panels 20 welded between
At each corner of the module 10, a fastening element
in the form of a respective corner casting 21 is provided.
Each corner casting 21 is of the kind conventionally found
on freight containers and is of hollow construction with
external top, side and end apertures 22 providing access
into the interior of the casting. Each casting 21 is made
generally in accordance with ISO/TC-104-1161 but with
variations in the external length of the casting in some
cases and with the front apertures of the upper castings
being in accordance with the dimensions set by the standard
for the fron apertures of the bottom castings.
Fig. 2 shows one particular internal wall construction
that may be employed in the module of Fig. 1. In the
example shown steel studding 23 of "L" shaped section is
stitch welded to the interior of a steel panel 20, boards
of insulation 24 are laid between the studding 23 and
plywood 25 is then fixed to the studding 23 over the
insulation 24.
Fig. 3 shows one particular floor construction that
may be employed in the module of Fig. 1. Steel floor
joists of inverted "L" shaped section 30 (or alternatively
of "C" section) are fixed over the corrugated steel panel
20, boards of insulation 31 are laid between the joists 30,
and plywood 32 is then fixed to the joists 30 over the
insulation 31.
Fig. 4 shows schematically the assembly of four
modules. A lower storey of modules 10A and 10B, each
similar to the module 10 of Fig. 1, have been placed in
position together with a module IOC which is directly above
the module 10A. Fig. 4 shows a fourth module 10D being
lowered into position on top of the module 10B to form a
building comprising four modules. The manner in which the
modules are fastened together is described below.
Fig. 5 shows one possible layout for a storey of
modules, in this case providing bedroom accommodation that
might typically be used for hotel, key workers or students.
The storey shown comprises a single row of modules
comprising two sets of four modules 50 with another module
51 interposed between each set and with further modules 52A
and 52B at respective ends of the row of modules. The
modules 50 within a given set are placed directly alongside
one another without any stagger whilst the module 51, which
is the same size and shape as the modules 50, is offset
from the adjacent sets of modules 50. The further
modules 52A and 52B are of a different shape from the
modules 50 and 51 being shorter and wider.
Each of the modules 50 may be of the general structure
shown in Fig. 1 with the openings 16 in the end faces of
the modules providing exterior window openings and the
openings 15 in the side faces of the modules allowing the
creation of a central corridor 53 through the modules. As
shown in Fig. 5, the modules 50 are internally divided by
partitions 54 having doors 55 to define the walls of the
corridor 53 and bedrooms 56 on each side of the corridor,
two bedrooms being thereby created within each module 50.
In the example shown, the module 51 with openings in
its side faces aligned with the corridor 53 contains at one
end of the module a staircase 57 allowing access to a lower
and/or upper storey through an opening in the roof and/or
floor of the module 51. At the opposite end of the
module 51 there is a space which may be used for services
and/or a lift. In the particular example shown the further
modules 52A and 52B are kitchens and each have three
windows 58. The storey is shown without any external
access but of course it should be understood that if
external access is required, that can readily be provided,
for example by providing an opening in an end face of the
module 51 and forming a doorway in the opening.
Each of the bedrooms created in the modules 50 is
shown fitted with a bathroom pod 59. Such pods which may
for example include a toilet, washbasin and shower are
known per se as prefabricated units and will not be
described further here.
Figs. 6A to 6D show possible variations of the basic
configuration of a module. In Fig. 6A a module 60 with
open end faces, a full height opening 61 in one side and a
window opening 62 in the opposite side is shown. In
Fig. 6B a module 63 with an open side face, an opposite
closed side face and two end faces with window openings 64
is shown. In Fig. 6C a module 65 with an open side face,
an open end face and with window openings 66 formed in the
other side and end faces is shown. Finally, in Fig. 6D a
module 67 with all its end and side faces open is shown.
Whilst certain particular configurations have been shown by
way of example, it will be understood that many other
The modules shown in Figs. 6A to 6D are approximately
1.5 times wider than the module 10 shown in Fig. 1. As
will be described below, the corner castings 21 of a
standard freight container are spaced apart by a standard
width (2259 mm centre-to-centre spacing) to allow the
container to be handled easily by conventional load
handling apparatus and engaged by fastening devices on
trailers. With a wider module, that spacing for
conventional load handling apparatus can no longer be
achieved by the corner castings 21 provided at the corners
of the modules and an additional casting 68 is therefore
provided along each top and bottom end rail 18 at the
standard spacing from one of the corner castings 21. That
enables the module to be readily handled by load handling
apparatus engaging the additional casting 68 and the
appropriate corner casting 21 on the same end rail 18. A
pair of extra castings 69 are also provided on the bottom
end rails 18 and on the top end rails 18, symmetrically
positioned on opposite sides of a central vertical
longitudinal plane through the module, at the standard
separation (2259 mm centre-to-centre spacing). Those extra
castings 69 allow a module to be fastened to standard
fasteners on a road trailer with the module symmetrically
placed on the road trailer and to be lifted symmetrically
by standard lifting equipment.
It will be understood that the castings 68 and 69, not
being at corners of the module have fewer apertures and
indeed the castings 69 may have apertures only in their end
faces or bottom/top faces if that is all that is required
to secure them to a road trailer and lifting equipment.
In addition to employing modules in accordance with
the invention as described above it is possible to use
extra modules of special design to suit particular
circumstances. For example it may be desirable to create a
high open space within a building or on a side of a
building and in that case an arrangement of the kind
exemplified in Fig. 7 may be employed. The structure shown
in Fig. 7 is an open span structure formed from a lower
module 71 having a bottom face 72 and end faces 73 but no
side faces and no top face, and an upper module 74 having a
top face 75 and end faces 76 but no side faces and no
bottom face. The modules 71 and 74 may be constructed as
rigid structures or they may be formed from separately
detachable panels allowing a flat pack style of transport.
It may be noted that each module is provided with corner
castings 21 at its eight corners.
An important feature of the described embodiments of
the present invention is the fastening system that enables
modules to be fastened together on site quickly,
economically and securely. One exemplary form of that
fastening system is shown in Figs. 8A to 8C and 9A to 9G
and will now be described with reference to those drawings
in which Figs. 8A to 8C provide an overview of the system
and Figs. 9A to 9G provide details of the various parts of
Referring first to Fig. 8A, which is an exploded view,
there are shown a corner casting 21A of a lower module, a
corner casting 2 IB of an adjacent lower module, a corner
casting 21C of an upper module stacked directly on top of
the module with the casting 21A and a corner casting 2ID of
an upper module stacked directly on top of the module with
the casting 21B. As will be understood, only the corner
castings of the modules and not the remaining parts of the
modules are shown in the interests of clarity.
A connector element 81 comprises in a single casting a
central plate part 82, lugs 83A and 83B projecting
downwardly from the plate part 82 and lugs 83C and 83D
projecting upwardly from the plate part 82. The lugs 83A
and 83B pass through apertures 84 in a lower gasket 85 and
into the apertures 22 in the tops of the castings 21A
and 21B. Similarly the lugs 83C and 83D pass through
apertures 86 in an upper gasket 87 (identical to the lower
gasket 85) and into the apertures 22 in the bottoms of the
castings 21C and 21D.
Once the connector element 81 is installed as
described, the corner castings 21A to 2ID are positioned as
shown in Fig. 8B. Lock down plates 88A and 88B, each
carrying a pair of lugs 89A and 89B are then able to be
inserted into the end apertures 22 of the corner castings.
Fig. 8B shows the plates 88A and 88B about to enter the
The plates 88A and 88B have holes 90 which pass
through the plates and the lugs 89A and 89B and align with
threaded holes 91 in the lugs 83A to 83D of the connector
element 81 when the corner castings 21A to 21C are properly
assembled together. Then, as a final stage of fastening,
bolts 92A to 92D with washers 93A to 93D are passed through
the holes 90 and into screw threaded engagement in the
holes 91 of the lugs 83A to 83D. The parts are then in the
position shown in Fig. 8C.
Figs. 9A to 9G illustrate the assembly just described
in more detail. It uses a connector element of the kind
shown in Fig. 9C having a central plate part 82 and four
lugss 83A, 83B, 83C and 83D (of which only 83C and 83D are
visible in Fig. 9C). That connector element is shown in
perspective view in Fig. 9H.
It will be noted that the fastening system just
described is suitable for joining four modules at
respective adjacent corners. It will be appreciated that
in other parts of the building, for example at a corner,
there will be only one upper and one lower corner casting
so that a connector element with only one lug on each side
will be required. Fig. 9J shows such a connector element
having a central plate part 82 and lugs 83A and 83C.
Similarly, it will be appreciated that in some parts of a
building having a three-dimensional array of modules it
will be desirable to provide a connector element with four
lugs on each side. Fig. 9K shows such a connector element
having a central plate part 82 and lugs 83A to 83H.
It should be understood that whilst one particular
locking system has been shown and described with reference
to Figs. 8A and 8B and 9A to 9G, other locking arrangements
may be provided, for example to suit the accessibility of
the connecting element. The lugs of the connector elements
also ensure accurate alignment of modules as the modules
are positioned on a partly constructed building.
Figs. 10 and 11 show certain additional features which
may be incorporated in a module according to the invention.
For example, if it is desired to provide a brick covering
over a face of the module, slots 101 may be provided in the
steel panel 20 forming the end face, "T" shaped brick ties
102 may be slotted into the slots 101 and a brick shelf 103
may be fixed at the bottom of the end face. As shown in
Fig. 10 the brickwork may be formed around a window 104.
Fig. 11 also shows how pods, for example a bathroom pod or
a kitchen pod, can be inserted through a side opening in
the module to allow installation of such a module on site
or prior to delivery to site.
Fig. 12A shows one example of a module, which may for
example be the module 52A shown in Fig. 5. Most of the
features of the module have been described above and are
referenced by the same reference numerals in Fig. 12A. A
further feature shown clearly in Fig. 12A is the provision
along all the horizontal rails of fixing points 120 to
which cladding systems, roof support systems or the like
may be fixed. In one particular example the module 52A
would have the following dimensions:
overall exterior length, 1: 6096 mm
overall exterior height, h: 2900 ram
centre-to-centre distance of additional
casting 68 from further
corner casting on same end rail, d: 2259 mm
centre-to-centre separation of extra
castings 69, x: 2259 mm
It will be understood from the description above that
the castings may be arranged in various ways according to
the size of the module and the handling and connecting
facilities that are required. Fig. 12B shows one
especially advantageous arrangement of castings at an end
of a module. In the arrangement shown there are four
corner castings 21, a further four castings 69A, 69B, 69C
and 69D along the top of the end of the module and a still
further four castings 69A', 69B', 69C' and 69D' along the
bottom of the end of the module. The other end of the
module has the same arrangement of castings.
The castings are arranged symmetrically about the
central vertical plane of the module indicated by the
centre line C/L in Fig. 12B. Each of the castings 21, 69
is arranged at the standard spacing from another casting,
that is at a distance marked D in Fig. 12B of 2438 mm
measured from the outer edges of the castings (resulting in
a centre-to-centre spacing of the apertures in the castings
of about 2260 mm).
Usually, if the module is to be lifted by standard
equipment for handling freight containers, then as shown in
Fig. 12C and illustrated by solid line arrows, a
spreader 95 will be lowered to engage the castings 69A
and 69D at each end of the module. The weight of the
module can then be evenly distributed on the spreader.
Similarly, when locking down the module on, for example, a
trailer chassis the module can be symmetrically positioned
by using the castings 69A' and 69D' as implied by the
dotted line arrows 96 in Fig. 12C. It should be noted,
however, that another possibility is to position the module
asymmetrically by using either of the castings 69B'
or 69C', together with one of the corner castings 21; the
dotted line arrows 97 in Fig. 12C illustrate this
arrangement which may be useful when the module is stored
on a container ship or is used in a building where it is
desired to offset the modules in one storey from those in
an adjacent storey.
It will be appreciated that although in Fig. 12B
additional castings are shown only at the ends of the
modules, they may also be provided partway along the
lengths of the top and bottom side edges of the modules.
Furthermore they may be provided away from the edges of any
of the faces of the module if desired, for example for
fixing other structural elements to the building. Thus,
the castings may be in the region of the ends rather than
at the ends of the module.
Fig. 13 shows a module such as the module 10 of Fig. 1
being placed on a foundation interface ring 130. The
ring 130 is placed on an appropriate foundation and locked
to it in an appropriate manner known per se. On the upper
face of the ring 130 there are upwardly projecting
connectors 131 of similar form to the connector elements 81
but with lugs 132 projecting on one side only from a
plate 133 welded to the ring 130. In the example shown the
connectors 131 each have a single lug 132 but it will be
understood from the description above with reference to
Figs. 8A to 8C and 9A to 9G that they may also have a pair
of lugs. The lugs 132 have screw threaded holes (not
visible in Fig. 13) for receiving bolts that secure
modified versions of the lock down plates 88A and 88B
described above (the plates being modified such that each
carries a single lug only with the bolt passing through the
lug and into the screw threaded hole in the connector 131).
It will be noted that the ring 130 is dimensioned to match
the length of a module so that opposite ends of the module
can be fastened to opposite sides of the ring. Special
manual or automatic twist lock or other mechanically locked
down connectors that can directly connect the modules to
the foundations may be provided.
Fig. 14 shows a module 140 of similar dimensions to
the module 10 described above together with another
module 141 of the same height and width, but a much shorter
length connected at the end of the module 10. The
combination of the two modules preferably has a standard
length, for example 40 ft (12192mm). Such an end-to-end
connection may provide a useful way of transporting the two
modules together even if the short module is subsequently
used in a different location in the building.
Fig. 15 shows a section through the floor, ceiling and
external walls of two modules 151 and 152 stacked on top of
one another. In the example shown windows 153 and 154 are
provided in the modules 151 and 152 and brickwork 155 is
provided on the exterior wall between the windows. The
lower module 152 is shown with a pressed steel corrugated
roof pan 156 below which are insulating panels 157A, a
plywood lining 158A and a plasterboard finish 159A. The
insulation panels 157A are held in place by XXL" shaped
sections 160A welded to the roof pan 156. In a similar way
the floor of the upper module 151 comprises a pressed steel
corrugated bottom face 161 on which insulating panels 157B
are laid and secured in place by "L" shaped sections 160B
welded to the steel corrugated face 161. A plywood floor
158B is laid over the panels 157B.
Fig. 16A shows a section (in plan view) through one
example of an external wall structure. A corrugated steel
skin 163 provides the structural strength and on the inside
carries insulating panels 157C held in place by "L" shaped
sections 160C. A plywood lining 158C is secured over the
panels 157C and a plasterboard finish 159C is added. On
the outside the steel skin 163 has a layer of
insulation 164 and outside that brickwork 165 held to the
skin 163 by ties which engage in slots 166 formed in
plates 167 welded to the steel skin 163.
Fig. 16B shows a section (in plan view) through one
example of adjoining internal walls 168A, 168B of adjacent
modules. Each wall is of the same construction including a
corrugated steel skin 163 which is exposed on its outer
face confronting the adjacent module and on its inner face
carries insulating panels 157D held in place by "L" shaped
sections 160D welded to the skin 163. A plywood
lining 158D is secured over the panels 157D and a
plasterboard finish 159D is added.
Whilst certain particular embodiments of the invention
have been described, it should be understood that these are
of course only examples of many different possible
arrangements. In the illustrated examples an upper storey
of modules is placed directly above a lower storey and the
modules in the upper storey are the same size as the
modules in the lower storey. It should be understood,
however, that this need not be the case. For example, the
modules in the upper storey may be bigger or smaller than
the modules directly below and/or the modules in one storey
may be offset from the modules in another storey. In cases
of this kind it is of course desirable for modules to have
fastening elements partway along their edges so that the
modules in one storey can be connected securely to the
modules in another storey.
In the particular example of buildings illustrated,
bedroom accommodation is provided. It will be understood
that the modules may be employed in a variety of
applications including housing, hotels, hostels, hospitals,
care homes, and educational, social and leisure facilities,
and in commercial, penal or industrial premises. Other
applications include basements and cellars, car parking and
storage. The accommodation provided by a module can take
many forms including bedrooms, living rooms, dining rooms,
kitchens, bathrooms, corridors, service voids, storage,
bicycle sheds, stairwells, lift shafts, launderettes,
community spaces and offices.
The buildings that are formed from the modules can be
permanent building structures with a life expectancy as
great or greater than those of a conventional building, and
they can also easily be extended, converted or modified.
Furthermore, if desired, a building can readily be
dismantled and the modules moved elsewhere.
It will be understood that appropriate services can
also be provided in the modules. Services may be run under
floors, above ceilings through specially formed ducts etc.
The modules may be provided with openings in appropriate
locations to allow services to pass from one module to
Fig. 17A shows a large module 200 with various
auxiliary parts displaced, as shown by dotted lines, to
enable the construction to be better understood. The
module 200 includes panels 201 in its top and 201' in its
bottom, which are removed on site to provide a vertical
passageway for a service duct. It also includes bracing/
sealing panels 202, 203 and 204 which add strength to the
module while it is being transported and lifted but can be
removed on site to provide openings, and it further
includes brick shelves 205 fixed along the bottom of the
side to support brick cladding.
Fig. 17B shows two of the modules 200 of Fig. 17A
mounted one on top of another, together with a further,
smaller module 300. The smaller module 300 has a side
opening that corresponds to a side opening in the
module 200, has a brick shelf 305 and a bracing panel 302.
The modules are shown connected to foundations 99.
Fig. ISA shows how the ground floor of the building
shown in Fig. 17B may be fitted out. The building includes
door openings 211 and 311 to the outside at one end of the
building and window openings 212 and 312 at the other end.
As shown there is provided on the ground floor a living
room 315, a kitchen 215, a bathroom 216 and a first bedroom
217. On the first floor there is a second bedroom 218 and
a bathroom 219 together with a third bedroom 220 which has
a door onto a roof terrace 316 formed by part of the top of
the module 300. At one end of the first floor a balcony
221 is connected to the upper module 200 and at the other
end there is a large window. Figs. 18C and 18D show
external elevations that can be obtained in the case of a
building of this type.
1.	A building module (10) having an exterior shape generally of a cuboid having side (12), end (11), top (13) and bottom (14) faces, and fabricated from metal, the module (10) being hollow and defining a space of a size suitable for occupation by a person, the module (10) being provided with fastening elements (21, 69) to allow the module (10) to be fastened to another adjacent module, wherein the module (10) has an overall exterior width greater than 2700 mm and has a first set of fastening elements (21, 69A, 69B, 69C, 69D) in the region of a first end of the top (13) of the module (10) and a second set of fastening elements (21, 69A, 69B, 69C, 69D) in the region of a second end of the top of the module (10), the fastening elements of each set having two fastening elements (e.g. 21, 69C) spaced apart from one another at a centre-to-centre spacing (D) of about 2260 mm, said fastening elements (21, 69) allowing engagement by standard load handling equipment for handling freight containers.
2.	A building module as claimed in claim 1, wherein the two fastening elements (21, 69) are symmetrically positioned on opposite sides of a central vertical plane of the module (10).
3.	A building module as claimed in claim 1 or 2, wherein each of the first and second sets of fastening elements comprises more than two fastening elements (68) at locations spaced across the top of the module each fastening element being spaced from another fastening element at a centre-to-centre spacing (D) of about 2260 mm.
4.	A building module as claimed in claim 1 to 3, wherein each of die first and second sets of fastening elements (21, 69) has fastening elements at the opposite side edges of die top of the module (10).
5.	A building module as claimed in any preceding claim, wherein the first and second sets of fastening elements (21, 69) are provided at opposite ends of the module (10).
6.	A building module as claimed in any preceding claim, wherein respective elongate members (17, 18, 19) are provided in the region of each of the eight edges of the cuboid and a plurality of metal panels (20) secured to at least some of the elongate members (17,18,19).
7.	A building module as claimed in claim 6, wherein the metal panels (20) are secured on
all of the side (12) and end (11) faces of the cuboid.
8.	A building module as claimed in any preceding claim, wherein there are metal panels (20) secured on the top (13) and bottom (14) faces of the cuboid.
9.	A building module as claimed in claim 7 or 8, wherein at least some of the metal panels (20) are corrugated.
10.	A building module as claimed in any of claims 7 to 9, wherein at least some of the panels (20) are of composite construction and include insulating material.
11.	A building module as claimed in any preceding claim, wherein one or each side (12) face of the module (12) is partly closed by a panel (20) and is pardy open (15).
12.	A building module as claimed in any preceding claim, wherein one or each end (11) face of the module (10) is partiy closed by a panel (20) and is partiy open (16).
13.	A building module as claimed in claim 11 or 12, wherein the partly open face or one of the pardy open faces extends from a region at the bottom of the face to a region at the top of the face.
14.	A building module as claimed in any of claims 11 to 13, wherein the pardy open face or one of the pardy open faces extends upwardly from a region partway up the face.
15.	A building module as claimed in any preceding claim, wherein a kitchen pod containing kitchen fittings is provided occupying a minor part only of the interior volume of the module (10).
16.	A building module as claimed in any preceding claim, wherein a bathroom pod containing bathroom fittings is provided occupying a minor part only of the interior volume of the module (10).
17.	A building module as claimed in any preceding claim, wherein the module (10) is provided with fastening elements (68) for fastening die module to an adjacent module placed alongside, or in an end-to-end relationship or placed immediately above or below.
18.	A building module as claimed in any preceding claim, wherein at least some of the fastening elements (21, 68, 69) are provided in the region of the eight corners of the module (10).
19.	A building module as claimed in any preceding claim, wherein at least some of the fastening elements (21, 68, 69) are defined by hollow blocks with openings (22) through which connector elements (81) can be inserted.
20.	A building module as claimed in claim 19, wherein at least some of the fastening elements (21, 68, 69) are provided with openings (22) in their top, side and end faces, or bottom, side and end faces.
21.	A building module as claimed in claim 19 or 20, wherein connector elements (81) are fastenable in said hollow blocks (21) after insertion into an opening (22) in said hollow block (21).
22.	A building module as claimed in claim 21, wherein die connector element is fastened in the opening (22) after insertion into said opening (22) by a fastener entering the hollow block (21) through another opening and engaging the connector element (81).
23.	A building module as claimed in claim 21 or 22, wherein the connector elements (81) are fastened in the hollow blocks (21) by fasteners screw threadedly engaging the connector elements (81) in the hollow blocks (21).
24.	A building module as claimed in any of claims 19 to 23, wherein the connector elements (81) have a connector element that has a first part for insertion into an opening in one fastening element (21) of one module (10) and a second part for insertion into an opening in another .fastening element of another module.
25.	A building module as claimed in any of claims 19 to 24, wherein at least one connector element (81) has a first, second, third and fourth parts (83A, 83B, 83C, and 83D) for insertion into openings in respective fastening elements of first, second, third and fourth modules.
26.	A building module as claimed in any of claims 19 to 24, wherein at least one
connector element (81) has eight parts (83A to 83H), each for insertion into a respective opening in a fastening element of a respective one of eight modules.
27.	A building module as claimed in any preceding claim, wherein additional fastening elements (101, 104) are provided partway along the bottom end (14) edges of the module (10).
28.	A building module as claimed in any preceding claim, wherein fhe overall exterior width of the module is in the range of 2700 mm to 5000 mm.
29.	A building module as claimed in any preceding claim, wherein the overall length of the module is selected from the range of 6000 mm to 6100 mm, 12100 mm to 12300 mm, and 13600 mm to 13800 mm.
30.	A building module as claimed in any preceding claim, wherein the exterior of the module (10) is fitted with a plurality of additional fastening elements (120) for interfacing with an external wall cladding system and/or a roofing system.
31.	A building module as claimed in claim 1, wherein the overall exterior width of the module is in the range of 2350 mm to 3700 mm or in the range of 2350 mm to 2500 mm.
32.	A building module as claimed in claim 1 or 31, wherein additional fastening elements are provided partway along the top end edges of the module.
33.	A building module substantially as herein described with reference to the accompanying drawings.
1512-DELNP-2006-Abstract-(02-06-2009).pdf
1512-delnp-2006-abstract-(04-06-2009).pdf
1512-delnp-2006-abstract.pdf
1512-DELNP-2006-Claims-(02-06-2009).pdf
1512-DELNP-2006-Claims-(04-06-2009).pdf
1512-delnp-2006-claims.pdf
1512-DELNP-2006-Correspondence-Others-(02-06-2009).pdf
1512-DELNP-2006-Correspondence-Others-(04-06-2009).pdf
1512-delnp-2006-correspondence-others-1.pdf
1512-delnp-2006-correspondence-others.pdf
1512-delnp-2006-description (complete).pdf
1512-DELNP-2006-Drawings-(02-06-2009).pdf
1512-delnp-2006-drawings.pdf
1512-delnp-2006-form-1.pdf
1512-delnp-2006-form-18.pdf
1512-delnp-2006-form-2.pdf
1512-DELNP-2006-Form-3-(04-06-2009).pdf
1512-delnp-2006-form-3.pdf
1512-delnp-2006-form-5.pdf
1512-delnp-2006-gpa.pdf
1512-DELNP-2006-Others-Documents-(04-06-2009).pdf
1512-delnp-2006-pct-101.pdf
1512-delnp-2006-pct-210.pdf
1512-delnp-2006-pct-306.pdf
1512-DELNP-2006-Petition-137-(04-06-2009).pdf
1512/DELNP/2006
9 MANSFIELD STREET, LONDON, WIG 9NY, UNITED KINGDOM.
1 HEATHER, DAVID 2 EAST DRIVE, HIGH WYCOMBME, BUCKINGHAMSHIRE HP 13 6JN, GREAT BRITAIN
2 HARDING, RUFUS, HAROLD OLD FORGE COTTAGE, DUCK STREET, EBBESBOURNE WAKE, WILTSHIRE SP5 5JN, GREAT BRITAIN
3 MACDONALD, RODERICK, 114 WOODSFORD SQUARE, LONDON W 14 8DT, GREAT BRITAIN.
4 HARDING, COLIN, EWART 10 MILNER ROAD, BOURNEMOUTH BH4 8AD, GREAT BRITAIN
5 OGDEN, RICHARD, CLIVE HOLLY COTTAGE, STOKE WOOD, STOKE POGES, BUCKINGHAMSHIRE SL2 4AU, GREAT BRITAIN.
PCT/GB2004/004400
1 0324363.1 2003-10-17 U.K.