GB2418210A - Building module - Google Patents

Abstract

A building module comprises a rectangular base 10 with a series of vertical load-bearing elements, each of which comprises a column 12a or a stability panel 14a, there being a vertical load bearing element at or adjacent each corner, and intermediate vertical load bearing elements 14b, 14c, as necessary, either parallel or orthogonal to edges 16a, 16b of the base. The base and columns may be of concrete and concrete may be cast into a mould in which the columns are held in a vertical position so as to produce a unitary structure. The base may have stiffening ribs 20 underneath. The factory-made modules are stacked on site to produce a multi - storey building, and may be fitted out with non-load-bearing walls, ceilings, bathrooms and kitchens.

Description

Modular Volumetric Construction System [0001] This invention relates to

modular construction systems for building dwellings, work spaces and the like. The invention includes modules, buildings composed of modules and methods of manufacturing modules and constructing buildings from the modules.

2] There have been many proposals for modular building systems in an attempt to provide cheap and rapidly assembled buildings.

Many of these are limited in the number of stories that can be provided in a building to four or five. In many cases, the modules are essentially box structures relying on the strength of their walls to maintain support. It is therefore difficult to allow variation in the outer structure of the modules or a completed building since this may compromise its strength and stability.

3] This invention aims to provide a modular building system that can achieve buildings of ten to twelve storeys, with a high degree of flexibility of arrangement of internal space.

4] A first aspect of the invention provides a building module comprising a rectangular base with a series of vertical load-bearing ..: elements, each of which comprises a column or a stability panel, the ..

vertical load-bearing elements being positioned such that there is an element at or close to each corner of the base and intermediate elements as necessary along the one edge and the parallel edge. :e

5] A column is an upright member having a width that is ë significantly smaller than its height such that its main strength is in compression and it resistance to shear is significantly lower. A stability panel is a planar member whose width is of a similar scale to its height such that it has strength both in compression and in-plane shear.

6] The module can comprise up to three stability panels. the first of which extends at least part way along the one edge of the base, the second of which extends part way along the parallel edge, and the third of which extends in a transverse direction perpendicular to the one edge at least part way across the base.

7] Reinforcing ridges, or down-stand beams, can be formed on the underside of the base along the one edge and its parallel edge, and extending between these edges beneath the transverse stability panel.

The ridges provide structural support to the rectangular base and define recesses in the lower surface of the base.

8] The module can also include one or more non-load bearing walls fixed around the periphery of the base, within the periphery of the base, or both and, a ceiling fixed on top of the vertical load-bearing elements and/or non load-bearing wall elements.

9] The base can be extended so as to project outwardly beyond the vertical load-bearing elements.

0] A second aspect of the invention comprises a building comprising a number of modules arranged adjacent to one-another and/or in a stacked arrangement.

1] Stacked modules all have an aligned configuration of the vertical load-bearing elements.

2] A building formed from stacked modules resists overturning by the action of the stability panels to provide buildings up to 12 storeys high.

3] A third aspect of the invention comprises a method of making A. a module, comprising positioning vertical load-bearing elements in a predetermined arrangement relative to each other and relative to a former for the base, and casting the base in the former around the ends of the . . vertical load-bearing elements such that the vertical load-bearing elements are integral with the base.

4] Following formation of the integral base and vertical load- bearing element structure, non load-bearing walls can be mounted in the module and furniture, services, appliances and equipment installed in the module. A ceiling can subsequently be installed over the wall elements.

5] A fourth aspect of the invention comprises a method of constructing a building comprising preparing a number of modules in a first location, moving the modules to a second location, and arranging the modules adjacent to one-another and/or in a stacked configuration at the second location.

6] Once the modules are arranged, they can be connected to each other and services connected according to requirements.

7] In the accompanying drawings, Figure 1 shows a perspective view of one module according to an embodiment of the invention; Figures 2a-c show perspective, plan and finished plan views of a unit formed from two modules according to an embodiment of the invention; Figures 3 a-c show perspective, plan and finished plan views of a unit formed from two modules according to another embodiment of the invention; Figures 4 a-c show perspective, plan and finished plan views of a unit formed from three modules according to another embodiment of the invention; and Figures 5a-d show a two-level unit according to an embodiment of the invention. ..

8] The system according to the embodiment of the invention shown in the drawings consists of a reinforced concrete structural module. A..

. : This structural module is cast in a high precision repetitive process in a : factory. The nature of the base design and the design of the vertical load bearing elements allows a wide variety of module dimensions to be achieved, within the maximum dimensions defined by transport . requirements. Accordingly, it is possible to create a range of spaces with differing interior layouts. Once the structure is complete, the module is fitted out to the specific requirements of the building design, using processes conceived for manufacture but nevertheless resulting in finishes that are consistent with traditional interior design.

9] Figure 1 shows a perspective view of one module according to an embodiment. The module comprises a base 10 and vertical load- bearing elements comprising columns 12 and stability panels 14. In this particular case, the vertical load-bearing elements 12, 14 are formed from cast, reinforced concrete. These can be provided in different arrangements on the base as will be described below. The arrangement of vertical loadbearing elements in this embodiment is not the only way in which these can be presented within the scope of this invention. Subject to the basic arrangement rules given above, there is freedom to position the basic vertical load-bearing elements 12, 14 according to requirements.

Examples of different arrangements are described in relation to Figs 2 to 5 below.

0] There are essentially no limits on the plan dimensions of the module. However, it is often desirable to limit these in accordance with local transport regulations and crane lift limitations in order that the modules can be transported by road, for example, and lifted into place using readily available cranes. For example, a maximum base size of 10m x 4.2 m may be defined to fit in with this requirement. For the purposes of description of Figure 1, these base dimensions are assumed but are not limiting in any way within the scope of the invention.

1] The vertical load-bearing elements 12, 14 can be manufactured in advance for a number of module configurations. For A. example, columns 12 can be 2850 x 400 x 160 mm and the stability . panels can be 2850 x 2850 x 160 mm. While these basic dimensions may be retained for all elements 12, 14, they can of course be varied to suit requirements within the limits of whichever manufacturing process is ë used. The width of the stability panels 14 may be varied between 2850 and 2200 mm, for example, although these values are not limiting values. -

2] As can be seen in Fig 1, and in Figs 2-5 below, there is a vertical load-bearing element at each corner of the base. In Fig 1, these comprise columns 12a-c and a shear panel 14a which extends from the corner of the base 10 part way along one long edge 16 thereof. In the case of the stability panel 14a, its plane is obviously aligned with the edge 16. For the column elements 12, these are rectangular in section with the long side aligned with the edge 16. As will be apparent below, it is not essential that columns in corners are arranged thus and it may be appropriate to arrange a corner column having a rectangular section with its long side aligned with a short edge of a base. It is also not essential that the vertical load-bearing elements are positioned exactly at corners; it is sufficient that they are located in the corner region of the base.

3] As the base 10 is significantly longer than it is wide, vertical load-bearing elements are provided at point along the long edges 16a, 16b between the corner elements. In this case, these comprise further stability panels 14b, 14c. Panel 14b is positioned so as to extend perpendicularly from the long edge 16a across the base 10 towards the other long edge 16b. Panel 14c is positioned along the edge 16b.

4] The module is formed by arranging the vertical load-bearing elements 12, 14 as desired and casting the base 10 around them in a former as is described below. For the dimensions of module given above, the base 10 is formed to a thickness of 150 mm. Reinforcing ridges 18a, 18b are formed in the underside of the base 10 along the long edges 16a, 16b. A transverse reinforcing ridge 20 extends across the base 10 between the long reinforcing ridges 18a, 18b beneath the transverse stability panel 14b. The reinforcing ridges 18a, 18b, 20 have a thickness of 150 mm (i.e. the total base thickness at the ridges is 300 mm) and a width of 225 mm. As with all other dimensions, these are not limiting and ë I: can be selected to suit particular requirements. The effect of the ridges ë18a, 18b, 20 is to form recesses in the lower face of the base 10. These may be used for providing particular services or properties to a module or building as is described below. :.

5] The module described above demonstrates the particularly A. preferred arrangement having stability panels in a perpendicular ë arrangement. This gives the module shear stability in these perpendicular directions. Consequently, non-load bearing partitions can be provided in and around the module to divide up the volume according to requirements. Because the wall elements are the load bearing structures, these partitions can include full height opening windows and the like without compromising the structural strength of a module or building.

6] One or more modules can be arranged together to provide a dwelling unit. Multi-storey buildings can be formed by combining dwelling units adjacent to one-another and by stacking modules.

7] In Figures 2a-c, two modules 30, 40 are arranged in a side- by-side configuration. Each module comprises columns 32, 42 and stability panels 34, 44. A column 32, 42 is provided at each corner, there is a stability panel 34a, 44a part way along one edge 36a, 46a and a transverse stability panel 34b, 44b extending from this edge part way across the base. The end of panel 34a, 44a butts against the end of panel 34b, 44b but it is not necessary that there is any structural joint between the two. A further column 32a, 42a is positioned along the other long edge 36b, 46b. The base of each module 30, 40 is cast in the same manner as described above with reinforcing ridges 38, 48 under the long edges and transverse reinforcing ridges (not shown) under the transverse stability panels 34b, 44b. The unit is configured as a living unit. After each module 30, 40 has been manufactured with its base and vertical load- bearing elements, non-load bearing partitions 50, including doors 52 and windows 54 can be added to each module to define living spaces such as bedrooms 56, dining rooms 58 and living rooms 60. Appliances and equipment can also be added for rooms such as bathrooms 62 and A. kitchens 64. Ceiling panels (not shown) can then be installed on each unit which can be transported to site and installed. ë-

8] Figures 3a-c show another two-module unit (using : corresponding numbers to those of Figs 2a-c in the 70-80 series). In this case, one module 70 has a transverse stability panel 74b at one end. The other module 80 has a single stability panel 84a along one edge 86a. .

Again, each module can be fitted out with partitioning and appliances and equipment as is described above.

9] The units described above are formed from two modules of the same base dimensions. It is also possible to form units from modules of different base dimensions as is shown in Figure 4a-c (numbering in the 100-120 series). In this case, there are three modules, 100, 110, 120 each of different widths (e.g. 3.15 m, 2.7 m and 3.45 m respectively).

The narrowest module 110 is between the wider modules 100, 120. The outside modules 100, 120 each have vertical load-bearing elements at each corner and stability panels along long edges and transversely (in this case along short edges). The middle module 110 is somewhat different.

Since the outside modules 100, 120 can provide a large element of strength and stability to the middle module 110there is no transverse stability panel, the columns 112 are arranged with their long sides aligned in the transverse direction. These modules can be fitted out as before to create a living unit.

0] Modules can be combined in both side-by-side and one on top of another to create two-story units. Figures 5a-d show arrangements of such modules (numbering in the 140, 150, 160, 170 series). The lower level is formed from two modules 140, 150. While these are of different lengths, they are essentially as described above in relation to Figs 2a-c.

The upper level is formed from two modules 160, 170 which are positioned above the lower level. Module 160 has the same base dimensions and layout of vertical load-bearing elements as module 140.

However, since access is to be provided by stairs between the two, a stair aperture 165 is provided in the base of the module 160. The aperture does not interfere with any of the load bearing elements of the module.

Module 170 has a shorter base length than that of module 150 on which it .

sits. One end of the base portion 178 is omitted such that when the ..e module 170 is placed on top of module 150, the space in the end portion . e : 158, 178 is of double height. However, the arrangement of vertical load : bearing elements 172, 174 in module 170 needs to correspond to those of module 150 in order that the modules can be safely placed one on top of the other. Consequently, columns 172a are retained.

1] In each of the above cases, the base is shown as finishing at the edges on which the vertical load-bearing elements are positioned. The base can be extended beyond this to provide balconies or corridor structured between modules or units, to create full width glazing or to vary the position of the building edge from one module relative to another. Balconies or other such structures can also be added that extend beyond the edges.

2] In order to stack modules effectively, it is necessary that the vertical load-bearing elements are provided in an aligned arrangement at each level. However, as can be see in Figure 5, this does not mean that modules have to be identical in a stack.

3] The recesses formed in the lower surface of each base by the reinforcing ridges can be used for lighting, acoustic insulation and to run services such as water or electricity between rooms since they are closed by the ceiling panel of the module below.

4] The manufacture of modules preferably takes place off-site and can be performed in a factory-like process as is described in the

following example.

5] Initially, the recesses in the base are defined using appropriately-sized polyurethane forming blocks, spacers, and connection receivers positioned to define a module base. Pre-fabricated reinforcing bars are placed in the former as required. Pre-fabricated vertical loadbearing elements are then suspended over the former so as to extend into channels formed by the blocks, spacers and farmers, and final reinforcing bars added. Concrete is then poured into the former around the block and the ends of the vertical load-bearing elements and allowed to set. The A. a: vertical load-bearing elements are thus formed integrally with the base, A. avoiding the need for joints which in the past have been the cause of many problems. When set, the farmers and supports are removed and the basic module moved for further finishing. :e

6] Non-structural wall elements (partitions) are added with ëclosures (doors) and windows. The internal surfaces are then painted. . -

Major electrical, lighting and data cables, basic water and waste pipes and flooring are then laid in the module. Major fittings such as kitchen or bathroom appliances and equipment can then be fitted. Following this, the ceiling element is placed and electrical connections completed. The module can then be wrapped and sent for shipping to site.

7] The completed modules are brought to site and stacked in place on pre-constructed foundations. The stacked modules are connected to the neighbouring modules to produce a robust tied reinforced concrete frame structure. Stacks of ten to twelve storeys can be achieved in which stability is provided by the action of the stability panels. The building is then clad and roofed with traditional processes, finishes are applied to the interior joints between the modules and services are joined to central risers. The lack of reliance on any particular cladding finish means that buildings in accordance with the invention can be designed with a large range of exterior finishes - subject to the preferred architectural expression, it will not be possible to see whether the building was system- built when it is finished.

8] It will be appreciated that the examples given above are illustrative of the scope of the invention but that many changes may still be made. :. ëe. ë.. ...

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Claims (1)

1 A building module comprising a rectangular base with a series of vertical load-bearing elements, each of which comprises a column or a stability panel, the vertical load-bearing elements being positioned such that there is an element at or close to each corner of the base and intermediate vertical load-bearing elements as necessary along the one edge and the parallel edge.

2 A module as claimed in claim i, wherein, the module comprises at up to three stability panels, the first of which extends at least part way along the one edge of the base, the second of which extends part way along the parallel edge, and the third of which extends in a transverse direction perpendicular to the one edge at least part way across the base.

3 A module as claimed in claim 1, or 2, further comprising reinforcing ridges formed on the underside of the base along the one edge and * its parallel edge, and extending between these edges beneath any stability panel extending between the edges. . . see

4 A module as claimed in claims, wherein the ridges define recesses in the lower surface of the base. .. *

A module as claimed in any preceding claim, further comprising one or more non-load bearing walls fixed around the periphery of the base, within the periphery of the base, or both.

6 A module as claimed in any preceding claim, further comprising a ceiling fixed on top of the vertical load-bearing elements or non load- bearing wall elements.

7 A module as claimed in any preceding claim, wherein the base is extended so as to project outwardly beyond the vertical load-bearing elements.

8 A module as claimed in any preceding claim, wherein additional elements, optionally including walkways and balconies, are fixed to the ends of the ridges.

9 A building comprising a number of modules as claimed in any preceding claim arranged adjacent to one-another and/or in a stacked arrangement that resists overturning forces by the action of the stability panels.

A building as claimed in claim 9, wherein stacked modules all have an aligned configuration of the vertical load-bearing elements.

A.: 11 A method of making a module, comprising positioning vertical load all bearing elements in a predetermined arrangement relative to each other and relative to a former for the base, and forming the base in the former around the ends of the vertical load-bearing elements such that the vertical load-bearing elements are integral with the a'''. base. . Pe

12 A method as claimed in claim 11, comprising mounting non-load bearing walls in the module following formation of the integral base and vertical load-bearing element structure.

13 A method as claimed in claim 12, comprising installing appliances and equipment installed in the module.

14 A method as claimed in claim 11 or 12, comprising installing a ceiling over the wall elements.

A method of constructing a building comprising preparing a number of modules according to any of claims 1-9 at a first location, moving the modules to a second location, and arranging the modules in a side-by-side and/or stacked configuration at the second location.

16 A method as claimed in claim 15, comprising connecting the modules to each other and to services following arrangement of the modules : ese 8 (8 (8 8 e 868 8 e ë