U.S. patent application number 10/505960 was filed with the patent office on 2005-09-29 for modular building, prefabricated volume-module and method for production of a modular building.
This patent application is currently assigned to Open House Systems AB. Invention is credited to Broberg, Peter.
Application Number | 20050210762 10/505960 |
Document ID | / |
Family ID | 20287118 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210762 |
Kind Code |
A1 |
Broberg, Peter |
September 29, 2005 |
Modular building, prefabricated volume-module and method for
production of a modular building
Abstract
The invention relates to a modular building of the type that
comprises vertical frame columns (70) and a plurality of volume
modules (2) prefabricated of sheet metal profiles (18-32) and being
of rectangular horizontal section, which are supported by the
columns (70) on two or more floor levels. The volume modules (2)
are prefabricated with two frame edge beams (50) which are stronger
than said sheet metal profiles (18-32) and which are horizontally
extended along a respective upper end wall edge of the volume
module (2) and which are on the one hand linearly connected with
frame edge beams (50) of adjoining modules (2) on the same floor
level and, on the other hand, connected to the columns (70) in such
a manner that the horizontal position of the frame edge beams (50)
relative to the columns (70) is fixed. The invention also relates
to such a module and a method for manufacturing such a
building.
Inventors: |
Broberg, Peter; (Landskrona,
SE) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Assignee: |
Open House Systems AB
P O Box 171
Landskrona
SE
SE-261 22
|
Family ID: |
20287118 |
Appl. No.: |
10/505960 |
Filed: |
October 27, 2004 |
PCT Filed: |
February 26, 2003 |
PCT NO: |
PCT/SE03/00303 |
Current U.S.
Class: |
52/79.1 ;
52/79.9 |
Current CPC
Class: |
E04B 5/48 20130101; E04B
1/3483 20130101; E04C 3/10 20130101; E04B 5/10 20130101; E04C 3/32
20130101; E04B 1/34807 20130101 |
Class at
Publication: |
052/079.1 ;
052/079.9 |
International
Class: |
E04H 003/00; E04H
009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 27, 2002 |
SE |
0200607-0 |
Claims
1. A modular building, comprising a plurality of vertical frame
columns and a plurality of volume modules prefabricated of sheet
metal profiles and having a rectangular horizontal section, which
are supported by the columns on two or more floor levels, wherein
the volume modules are also prefabricated with two frame edge beams
which are stronger than said sheet metal profiles and which are
horizontally extended along a respective upper end wall edge of the
volume module and which are on the one hand linearly connected with
frame edge beams of adjoining modules on the same floor level and,
on the other hand, connected to the columns in such a manner that
the horizontal position of the frame edge beams relative to the
columns is fixed.
2. A modular building as claimed in claim 1, wherein the modules
are supported by the columns in such a manner that they are
vertically loaded only by their dead weight and payloads.
3. A modular building as claimed in claim 2, wherein the modules
are vertically supported at least in their lower corner portions by
the columns while said frame edge beams transfer essentially only
horizontal forces.
4. A modular building as claimed in claim 3, wherein the modules
rest on the flanges projecting horizontally from the columns.
5. A modular building as claimed in claim 4, wherein each frame
column consists of a number of separate column portions which each
at the its lower end have a horizontally projecting,
module-supporting flange.
6. A modular building as claimed in claim 4, wherein the lower
corner portions of the modules on the one hand and the
module-supporting flanges of the columns on the other hand are
provided with cooperating means which counteract lateral
displacement of the modules.
7. A modular building as claimed in claim 1, wherein each frame
edge beam is positioned between two frame columns in a vertical
plane common therewith.
8. A modular building as claimed in claim 7, wherein each pair of
two linearly interconnected frame edge beams has a first beam end
and a second beam end which are positioned on either side of an
intermediate frame column to form therewith a joint and which beam
ends are directly connected with each other with the aid of a
coupling means which bridges the frame column horizontally and on
opposite sides thereof to thus also fix the horizontal position of
the frame edge beams relative to the frame column.
9. A modular building as claimed in claim 8, wherein each frame
column is divided into linearly assembled column portions, and
wherein said coupling means is formed as a separate coupling
device, comprising on the one hand a horizontal top metal sheet
which in the erection of the building is mounted between two column
portions and, on the other hand, two vertical, mutually parallel
connecting metal sheets which project downwards from the underside
of the top metal sheet and which are extended on opposite sides of
the frame column and connected with the beam ends of the frame edge
beams.
10. A modular building as claimed in claim 1, wherein the sheet
metal profiles included in each module comprise two horizontal roof
edge profiles which each form an upper longitudinal edge of the
module and in which the two frame edge beams of the module are
supported.
11. A modular building as claimed in claim 10, wherein the frame
edge beams and the two roof edge profiles are located in a common
horizontal plane.
12. A modular building as claimed in claim 10, wherein the frame
edge beams are attached to the module in such a manner that
horizontal forces can be transferred between the roof edge profiles
and the frame edge beams perpendicular to the latter.
13. A modular building as claimed in claim 1, further comprising
horizontal, frame-stabilising surfaces in the form of panel
elements and/or framework.
14. A modular building as claimed in claim 13, wherein each module
is prefabricated with a roof panel elements fixed to the frame edge
beams of the module and wherein, on a given floor level, such floor
panel elements are interconnected to a horizontal frame-stabilising
surface.
15. A modular building as claimed in claim 1, comprising vertical,
frame-stabilising surfaces.
16. A modular building as claimed in claim 15, wherein the modules
are prefabricated with vertical wall elements, such as gypsum
boards, to form said vertical frame-stabilising surfaces.
17. A modular building as claimed in claim 1, wherein said sheet
metal profiles have a material thickness of less than 4 mm.
18. A modular building as claimed in claim 1, wherein said sheet
metal profiles have a material thickness in the range 0.5-3 mm,
preferably about 2 mm.
19. A modular building as claimed in claim 1, wherein the columns
and the frame edge beams are steel beams.
20. A modular building as claimed in claim 1, wherein the columns
and the frame edge beams are steel beams with a material thickness
of at least 4 mm.
21. A prefabricated volume module made of sheet metal profiles and
having a rectangular horizontal section, which module, together
with other such modules, is adapted to form a modular building in
which the modules are vertically supported by frame columns on two
or more floor levels, wherein the volume module is prefabricated
with two frame edge beams which are stronger than said sheet metal
profiles, said frame edge beams being horizontally extended along a
respective upper end wall edge of the volume module and, in the
modular building, linearly connected with frame edge beams of
adjoining modules on the same floor level.
22. A module as claimed in claim 21, wherein said sheet metal
profiles comprise two horizontal roof edge profiles, which each
form an upper longitudinal edge of the module and which support the
frame edge beams at the upper end wall edges of the module.
23. A module as claimed in claim 22, wherein each frame edge beam
has two opposite free beam ends which are located horizontally
outside the roof edge profiles and which, in the modular building,
are connected with corresponding free beam ends of adjoining
modules on the same floor level.
24. A module as claimed in claim 22, wherein the two frame edge
beams and the two roof edge profiles are located in a common
horizontal plane.
25. A module as claimed in claim 24, wherein the frame edge beams
extend through vertical openings of the frame edge profiles so as
to have said free beam ends on the outsides, directed away from
each other, of the roof edge profiles.
26. A module as claimed in claim 21, wherein the frame edge beams
are attached to the module in such a manner that transfer of
frame-stabilising horizontal forces is allowed between the roof
edge profiles and the frame edge beams perpendicular to the
latter.
27. A module as claimed in claim 26, wherein each frame edge beam
is attached to the two roof edge profiles by means of two
horizontal tension rods, which each have an end connected with the
frame edge beam and an end connected with the associated roof edge
profile.
28. A module as claimed in claim 27, wherein the roof edge profiles
are formed as C profiles in which said tension rods are
extended.
29. A module as claimed in claim 21, wherein the module is further
provided with one or more frame-stabilising surfaces in the form of
panel elements and/or framework.
30. A module as claimed in claim 21, wherein the module is provided
with a frame-stabilising surface in the form of a
horizontal-force-transferring roof panel element which is fixed to
the two frame edge beams.
31. A module as claimed in claim 30, wherein said
horizontal-force-transfe- rring roof panel element is made of
trapezoidal metal sheet.
32. A module as claimed in claim 30, wherein said
horizontal-force-transfe- rring roof panel element is fixed also to
at least some profiles among said sheet metal profiles which form
the roof of the module.
33. A module as claimed in claim 21, wherein the module is provided
with a frame-stabilising surface in the form of a
horizontal-force-transferring roof framework.
34. A module as claimed in claim 21, wherein the module is provided
with one or more frame-stabilising surfaces in the form of
vertical-force-transferring wall panel elements which are fixed to
the sides of the module.
35. A module as claimed in claim 34, wherein said wall panel
elements comprise gypsum boards.
36. A module as claimed in claim 21, wherein said sheet metal
profiles have a material thickness of less than 4 mm.
37. A module as claimed in claim 36, wherein said sheet metal
profiles have a material thickness in the range 0.5-3 mm,
preferably about 2 mm.
38. A module as claimed in claim 21, wherein the frame edge beams
are steel beams.
39. A module as claimed in claim 38, wherein the frame edge beams
are steel beams with a material thickness exceeding 4 mm.
40. A module as claimed in claim 21, wherein the frame edge beams
and the columns have essentially the same horizontal width.
41. A module as claimed in claim 21, wherein, in the modular
building, the lower corner portions of the module are supported by
flanges projecting horizontally from the columns, and wherein the
module further comprises means at its lower corner portions adapted
to cooperate with said flanges to prevent horizontal displacement
of the module relative to the columns.
42. A modular building comprising a plurality of modules as claimed
in any one of claims 21-41, wherein frame edge beams of adjoining
modules on the same floor level are linearly interconnected so as
to jointly transfer horizontal compressive forces and tensile
forces in the building.
43. A method for manufacturing a modular building, comprising the
following steps prefabricating rectangular volume modules of sheet
metal profiles, each module also being prefabricated with two frame
edge beams which are stronger than the sheet metal profiles and
which are horizontally extended along a respective upper end wall
edge of the module; and mounting at the building site the
prefabricated volume modules on two or more floor levels by means
of vertical frame columns, frame edge beams of adjoining modules on
each floor level being interconnected linearly before the modules
of the next floor level are mounted.
44. A method as claimed in claim 43, wherein the modules are
mounted so that they are vertically loaded only by their dead
weight and payloads.
45. A method as claimed in claim 44, wherein each frame column is
divided into a number of column portions corresponding to the
number of floor levels, and wherein frame edge beams of adjoining
modules on each floor level are interconnected linearly and
connected with the column portions of the floor level before the
column portions and the modules of the next floor level are
mounted.
46. A method as claimed in claim 45, wherein each column portion
has at its lower end a horizontally projecting bottom flange, and
wherein the step of mounting the volume modules comprises the
following substeps for each floor level before the next floor level
is mounted: mounting the column portions belonging to the floor
level, arranging the modules belonging to the floor level on top of
the bottom flanges of the column portions belonging to the floor
level, linearly interconnecting the frame edge beams of adjoining
modules, and connecting the beam ends of the frame edge beams with
the column portions belonging to the floor level.
47. A method as claimed in claim 46, wherein the substep of
interconnecting the frame edge beams of two adjoining modules and
the substep of connecting the beam ends of the frame edge beams
with the column portions are carried out as a common substep by
mounting a coupling means which is common for these
interconnections.
48. A method as claimed in claim 47, wherein the frame edge beams
are positioned between the frame columns in vertical planes common
therewith, so as to form joints where two opposite beam ends are
arranged on either side of a frame column and interconnected
linearly round the frame column by the common coupling means so
that the horizontal position of the frame edge beams relative to
the columns is fixed.
49. A method as claimed in claim 43, wherein the step of
prefabricating the volume modules comprises the following substeps:
manufacturing an open volume of sheet metal profiles, comprising
two horizontal roof edge profiles which each form an upper
longitudinal edge of the module and which have vertical openings at
the end walls (6) of the module, and mounting the frame edge beams
in the vertical openings of the frame edge profiles so that the
frame edge beams on the outsides, directed away from each other, of
the roof edge profiles have free beam ends for linear connection
with such free beam ends of the frame edge beams of adjoining
modules.
Description
FIELD OF THE INVENTION
[0001] The invention relates generally to the technical field of
modular buildings and concerns on the one hand a modular building
and, on the other hand, a volume module and a method for
manufacturing the same. More specifically, the invention concerns
modular buildings of the type having a plurality of prefabricated,
essentially identical volume modules of rectangular horizontal
section, which are vertically supported by vertical frame columns
on a plurality of floor levels so that each of them is only loaded
by its dead weight and payload.
[0002] The invention makes it possible to manufacture such modular
buildings using so-called lightweight construction engineering (in
contrast to traditional building constructions) and with
industrially prefabricated lightweight modules that require a small
number of mounting operations at the building site.
BACKGROUND ART
[0003] WO 91/05118 discloses a modular building of the above type
comprising a skeleton or frame construction consisting of vertical
frame columns and horizontal bars and beams which are joined with
each other in a torsionally rigid manner in joints of the frame
construction. The larger the building, the higher construction
requirements are placed on the rigidity of the frame of the
building. Both horizontal forces (wind forces) and vertical forces
(payloads and dead weights) are transferred to the frame
construction.
[0004] A drawback of this prior-art building according to WO
91/05118 is precisely the existence of and requirements for such
torsionally rigid joints. It is a major technical problem to
satisfy all the rigidity requirements that are placed on a modular
building, especially the torsionally rigid joints where different
materials, forces and functions meet. Joints belong to the most
difficult problems in construction engineering. The time required
at the building site for forming the joints is also an important
factor.
[0005] SE 9404111-8, which concerns a solution to the above
problems, discloses a modular multistorey building which, with
respect to force take-up, is divided into on the one hand an inner
zone, which takes up vertical forces and comprises frame columns
with the volume modules suspended therefrom on several floor levels
and which essentially does not take up any lateral forces acting on
the building and, on the other hand, a fa.cedilla.ade zone, which
is arranged immediately outside the inner zone and adapted to take
up lateral forces for lateral stabilisation of the inner zone and
hence the entire building. The fa.cedilla.ade zone comprises a
plurality of fa.cedilla.ade panel elements distributed along the
outside of the inner zone and vertically oriented perpendicular to
the fa.cedilla.ade of the building. In this solution, use is not
made of horizontal beams as included in prior-art frame
constructions. The payloads and dead weights of the modules are
distributed over and taken up by the columns in the inner zone
while most of the horizontal wind forces acting on the building are
taken up by the fa.cedilla.ade panel elements arranged
perpendicular to the fa.cedilla.ade in the fa.cedilla.ade zone
outside the inner zone.
[0006] While the problem of torsionally rigid joints is at least
partially solved in SE 9404111-8, a new problem arises, viz. that
the required size and cost of the horizontally stabilising
fa.cedilla.ade zone rapidly increase as the number of floors in the
building increases. Besides, the solution involving a special
fa.cedilla.ade zone is in itself not quite satisfactory.
SUMMARY OF THE INVENTION
[0007] One object of the invention is therefore to provide a
solution for modular building systems of the type stated by way of
introduction, which eliminates or at least reduces the above
problems.
[0008] According to a first aspect of the invention, a modular
building is provided, comprising a plurality of vertical frame
columns and a plurality of volume modules prefabricated of sheet
metal profiles and having a rectangular horizontal section, which
are supported by the columns on two or more floor levels. The
building according to the invention is characterised in that the
volume modules are also prefabricated with two frame edge beams
which are stronger than said sheet metal profiles and which are
horizontally extended along a respective upper end wall edge of the
volume module and which are on the one hand linearly connected with
front edge beams of adjoining modules on the same floor level and,
on the other hand, connected to the columns in such a manner that
the horizontal position of the frame edge beams relative to the
columns is fixed.
[0009] According to a second aspect of the invention, a method for
manufacturing a modular building is provided, comprising the
following steps:
[0010] prefabricating rectangular volume modules of sheet metal
profiles, each module also being prefabricated with two frame edge
beams which are stronger than the sheet metal profiles and are
horizontally extended along a respective upper end wall edge of the
module; and
[0011] mounting at the building site the prefabricated volume
modules on two or more floor levels by means of vertical frame
columns, frame edge beams of adjoining modules on each floor level
being interconnected linearly before the modules of the next floor
level are mounted.
[0012] According to a third aspect of the invention, a module is
provided for manufacturing a building as defined above and for use
in the method as defined above.
[0013] Preferred embodiments of the building, the method and the
module according to the invention are stated in the dependent
claims.
[0014] Since the modules that are used according to the invention
are made up of sheet metal profiles--and thus are to be considered
"lightweight modules"--it is preferred for the modules, in per se
prior-art manner, to be supported by the columns in such a manner
that they are vertically loaded essentially only by their dead
weight and payloads.
[0015] The sheet metal profiles from which the volume modules are
made preferably have a material thickness of less than 4 mm,
preferably in the range 0.5-3 mm. A preferred embodiment is in the
order of 2 mm.
[0016] The stronger frame edge beams included in the volume modules
consist, like the vertical frame columns, preferably of steel
beams, such as rolled steel, with a wall thickness which preferably
is greater than 4 mm.
[0017] The term "volume module" does not relate to a normally
closed volume in the first place, but rather a constructionally and
initially open room or framework of sheet metal profiles without
side walls, i.e. a module or cassette defined by geometric surfaces
(imaginary walls), referred to as an open system unit. Each "volume
module" included in a building according to the invention can be
adjusted entirely to the desired form and function of the building
and may especially constitute a room of its own or part of a room
with adjoining volume modules on the same floor level. Thus, the
volume modules can be provided with wall-forming vertical panel
elements, at the factory and/or at the building site, according to
how the building is divided into rooms.
[0018] According to the invention, the "prefabricated modules" are
prefabricated with at least their sheet metal profiles and their
frame edge beams. Prefabrication usually includes also many other
elements, such as board material, infill etc, as will be described
below. By "prefabricated" is here meant the state of the module
when being positioned in the column frame at the building site.
Normally, everything can be prefabricated at the factory, but it is
also conceivable that certain parts are mounted later, both before
and after positioning the modules in the column frame.
[0019] An advantage of the invention is that it makes it possible
to stabilise an open, column-supported lightweight structure for
taking up the complex of forces that arise in a building. High
material efficiency can be achieved by using lightweight
construction engineering.
[0020] The invention especially makes it possible to manufacture a
modular lightweight building from prefabricated volume modules,
here called lightweight modules. Use of industrially prefabricated
lightweight modules has in itself several advantages related to
precision, quality, cost and efficiency, such as a small number of
mounting operations at the building site and, thus, a short
building time.
[0021] A special advantage of the invention is that it makes it
possible--by means of the stronger frame edge beams at the upper
end wall edges of the modules--to partly integrate the frame
stabilisation into the lightweight modules. This can be expressed
in such a manner that parts of the frame stabilisation which in
prior-art systems are provided with a heavy, separate skeleton or
frame construction according to the invention are instead
integrated into the actual modules. By integrating the frame
stabilisation partly into the modules, the advantage is obtained
that the structure of the modules is reinforced and will have the
required stability in spite of its light construction. As will be
described below, additional components may also be included in the
modules for additional integration of the frame stabilisation into
the modules.
[0022] An advantage of the invention is that the modular building
can be manufactured in such a manner that joints positioned
adjacent to the columns need not take up moments for frame
stabilisation. In a preferred embodiment of the invention, in frame
stabilisation the joints are essentially intended merely for
horizontal and vertical transfer of forces whereas wind forces
acting on the building can instead be taken up by frame-stabilising
surfaces formed as panels and/or framework.
[0023] The invention makes it possible to achieve the above
advantages while at the same time the joints positioned adjacent to
the frame columns are designed in such a manner that the
lightweight modules in the fa.cedilla.ade of the building can be
extended horizontally past the joints. This gives a high degree of
flexibility and allows different house widths with the same base
module dimensions, without necessitating changes of the frame and
stabilising system (the same columns, the same volume modules, the
same beams, the same joints etc). Such requirements in connection
with different house widths are highly frequent.
[0024] According to a particularly preferred embodiment of the
invention, the concept "frame stabilisation integrated into the
modules" includes not only the above-mentioned frame edge beams,
but also what will below be referred to as "frame-stabilising
surfaces". The term "frame-stabilising surface" should here be
understood as a surface in the geometric sense and can be
implemented with panel elements and/or with framework.
Frame-stabilising surfaces included in the volume modules and the
building act to take up horizontal shear forces. This adds to the
fact that the joints between the frame edge beams and the frame
columns need not take up moments, which in turn makes construction
and erection less expensive and easier.
[0025] According to a particularly preferred embodiment of the
invention, each module is prefabricated with a roof panel element
fixed to the frame edge beams of the module and/or to the upper
longitudinal sheet metal profiles of the module. During mounting of
each floor level, the systems of joists are joined so that the
board effect thereof may be utilised. Thus, such roof panel
elements may be connected horizontally so as to jointly form a
larger frame-stabilising horizontal surface. Such frame-stabilising
surfaces can in turn be combined in a suitable manner with special
stabilising wall elements and/or staircases, for instance made of
steel or concrete in the traditional manner.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0026] The above and other advantages, features and preferred
embodiments of the invention will now be described in more detail
with reference to the accompanying drawings.
[0027] FIG. 1 is a perspective view of an embodiment of an
inventive volume module formed as a lightweight module.
[0028] FIG. 1A corresponds to FIG. 1 but shows a lightweight module
which is partly open.
[0029] FIG. 2 shows an enlarged detail of an upper corner of the
lightweight module in FIG. 1.
[0030] FIG. 3 shows schematically the roof plane of the lightweight
module in FIG. 1 and parts of an adjoining module.
[0031] FIG. 4 shows an enlarged detail of the area marked C1 in
FIG. 3.
[0032] FIG. 5 shows schematically the bottom plane of the
lightweight module in FIG. 1 and parts of an adjoining module.
[0033] FIG. 6 is a schematic side view of a long side of the
lightweight module in FIG. 1 and also shows two frame columns.
[0034] FIG. 7 is a schematic side view of an end wall of the
lightweight module in FIG. 1.
[0035] FIG. 8 shows an enlarged detail of the area marked C2 in
FIG. 7.
[0036] FIG. 9 is a broken-away vertical section which shows
trapezoidal metal sheets and side bars of two adjoining lightweight
modules.
[0037] FIG. 10 is schematic perspective view of a lightweight
module according to FIG. 1 supported by vertical frame columns.
[0038] FIG. 11 is a vertical section and shows parts of an
embodiment of a building according to the invention.
[0039] FIG. 12 is a schematic top plan view of an embodiment of a
building according to the invention formed as a 6-module system and
illustrates neutral zones between the modules.
[0040] FIG. 13 is a schematic top plan view of the 6-module system
in FIG. 12 and illustrates the principle of horizontal frame
stabilisation when subjected to wind loads.
[0041] FIG. 14 is a schematic top plan view of a building according
to the invention formed as a double module system and illustrates
horizontal frame stabilisation.
[0042] FIG. 15 is a vertical section according to FIG. 11
supplemented with force arrows that illustrate vertical frame
stabilisation.
[0043] FIG. 16 is a top plan view of a column portion.
[0044] FIG. 17 is a side view of the lower part of a column
portion.
[0045] FIG. 18 is a bottom plan view of a coupling device.
[0046] FIG. 19 is a first side view of the coupling device in FIG.
18.
[0047] FIG. 20 is a second side view of the coupling device in FIG.
18.
[0048] FIGS. 21 and 22 show in perspective from above and from
below, respectively, two column portions with an intermediate
coupling device.
[0049] FIG. 23 is a schematic horizontal section of a joint between
two modules on the same floor level.
[0050] FIG. 24 is a schematic side view--seen towards a frame
column--of a joint between two modules on adjoining floor
levels.
[0051] FIG. 25 is a schematic side view of a joint--seen from a
frame column--between two modules on adjoining floor levels.
[0052] FIG. 26 is a schematic exploded view of a joint between
three modules.
[0053] FIGS. 27-30 are schematic perspective views of a joint seen
from different directions and with different parts uncovered, to
illustrate the construction and function of the joint.
DESCRIPTION OF AN EMBODIMENT
[0054] With reference to the accompanying drawings, now follows a
description of an embodiment of a modular lightweight building
according to the invention, manufactured from volume modules
according to the invention and made by a manufacturing method
according to the invention. Like components have throughout been
given the same reference numerals.
[0055] Reference is first made to FIGS. 1-9, which show a volume
module, generally designated 2. The module 2 is intended to be
manufactured at a location other than the building site, preferably
at a factory so as to make it possible to utilise the advantages of
the factory in respect of rational handling of materials, quality
and efficiency. At the building site, the volume modules are
positioned by means of a crane. At the factory, the volume modules
can be customised according to requirements and be provided with
the necessary components. Since the entire inner mounting of infill
and installation components can also take place at the factory,
high-technological and accuracy-requiring operations can take place
within the controllable environment of the factory. They can thus
be equipped as sanitary modules, dwelling modules etc.
[0056] The wall faces of the module, i.e. its two long sides 4 and
its two short sides or end walls 6, can be opened so that a
completed room is made up of one or more modules 2, depending on
where wall elements are mounted on the volume modules. Such wall
elements can be factory-mounted and/or mounted at the building
site.
[0057] The volume module 2 is of rectangular horizontal section,
which in this embodiment has the dimensions 3.9 m*7.8 m, including
what is below referred to as "neutral zones" NZ between the modules
2 (FIGS. 12 and 23). The height of the module is in the shown
example 3 m (FIG. 11).
[0058] The volume module 2 is defined by the following geometric
planes (see FIGS. 3 and 5): two vertical side wall planes 4, two
vertical end wall planes 6, a horizontal roof plane 8 and a
horizontal bottom plane 10. The vertical planes 4 and 6 can be more
or less closed by means of board material, as schematically shown
at reference numeral 12 in FIG. 6.
[0059] The roof plane 8 and the bottom plane 10 of the module 2 are
normally closed by panel elements 14 and 16, respectively, of which
broken-away parts are shown schematically in FIGS. 1, 3 and 5 in
the form of trapezoidal metal sheet.
[0060] The volume module 2 is according to the invention made of
sheet metal profiles (beams/girders/bars/panel elements/trapezoidal
metal sheets). The sheet metal profile elements preferably have a
material thickness of 1-4 mm, preferably less than 3 mm and most
preferred less than or equal to 2 mm.
[0061] More specifically, the module 2 comprises the following
sheet metal profiles:
[0062] two top beams (roof edge profiles) 18 and two bottom beams
(bottom edge profiles) 20 which form the longitudinal edges of the
roof plane 8 and the floor plane 10;
[0063] a plurality of roof bars 22 and floor bars 24 which are
extended between and connected with the top beams 18 and the bottom
beams 20, respectively;
[0064] a plurality of vertical end wall bars 26 along the end wall
planes 6 of the module and a plurality of vertical side wall bars
28 along the side wall planes 4 of the volume module (vertical bars
can be excluded to some extent),
[0065] upper and lower horizontal, side wall bar carrying U
profiles 30 (FIG. 9) which extend along and are mounted on the
outsides of the top beams 18 and bottom beams 20 and in which the
vertical side wall bars 28 are inserted and joined,
[0066] upper and lower horizontal end wall bar carrying U profiles
32 (FIG. 25) in which the vertical end wall bars 28 are inserted
and joined, and
[0067] a horizontal U profile 34 (FIG. 25) along the lower edge of
each end wall plane 6 for mounting of insulation 36.
[0068] The end wall bars 26 and the side wall bars 28 in FIG. 1 can
be excluded, when required. The four corner bars and the two
central side wall bars 28' (FIG. 1) in each side wall plane 4
cannot, however, be excluded, but are required for transferring of
loads. FIG. 1A shows an example of a module 2 where one end wall 6
and one long side 4 have been half-opened for communication with
adjoining volume modules (not shown) in the completed building.
[0069] Wall boards 12, such as gypsum boards, fibreboards and
particle boards, are mounted on the vertical bars 26, 28, as
schematically shown in FIG. 6. For instance, six wall boards 12 can
be mounted along each module long side 4 in two relatively offset
layers. The inner layer is screwed to the vertical side wall bars
28.
[0070] According to the principle of the invention, the volume
module 2 is prefabricated with two frame edge beams 50 which are
stronger than the sheet metal profiles. The frame edge beams 50
have several purposes for force transfer, as will be described in
more detail below. They are used to transfer forces to adjoining
frame edge beams, adjoining frame columns, adjoining modules,
adjoining frame-stabilising surfaces and special frame-stabilising
systems. A special purpose of the frame edge beam 50 is to form tie
beams and compressed beams in connected modules on each floor
level.
[0071] The frame edge beams 50 consist in the shown example of
rolled steel beams having a square cross-section of 10*10 cm and a
material thickness of 5 mm.
[0072] The frame edge beams 50 are horizontally extended along a
respective upper end wall edge of the module 2 where they are
mounted in and carried by the two top beams 18. In the shown
preferred embodiment, the frame edge beams 50 and the two top beams
18 are located in a common horizontal plane coinciding with the
roof plane 8. This is advantageous both with regard to horizontal
force transfer between these components and with regard to the
possibility of extending the room volume of the module 2 in the
longitudinal direction of the modules past the frame edge beams 50.
More specifically, as best seen on a larger scale in FIG. 2, the
top beams 18 formed as C profiles are at their ends provided with
vertical openings, which preferably match the outer dimensions of
the frame edge beams 50. The frame edge beams 50 extend through
these openings and have on the outsides of the top beams 18 free
beam ends 52 formed with mounting holes 53 for a coupling device
that will be described below.
[0073] As best seen in FIGS. 3, 23-25 and 28, the stronger frame
edge beams 50 are attached to the lighter top beams 18 by means of
threaded tension rods 54, four for each module. As best seen in
FIG. 28, an angular fixing mount 56 for each tension rod 54 is
fixedly mounted in the top beam 18. Each tension rod 54 extends
through the fixing mount 56, through a hole in the outer roof bar
22 and through a hole in the frame edge beam 50. The tension rods
54 are fixed by means of plates 58 and nuts 60. The tension rods 54
serve to transfer horizontal forces between the frame edge beams 50
and the top beams 18 in the longitudinal direction of the latter.
In the first place, the tension rods 54 aim at taking up horizontal
forces which strive to displace the frame edge beams 50 away from
the module 2 in the longitudinal direction of the top beams 18.
[0074] As mentioned above, the roof plane 8 and the bottom plane 10
of the module 2 are normally closed by panel elements 14 and 16,
respectively, which in the preferred embodiment are made of
trapezoidal-profiled sheet metal, which can also advantageously
accompany the prefabricated module. The TRP metal sheet is used to
transfer horizontal forces to the corners of the module and the
frame edge beams 50. It is to be noted that the panel elements 14,
16 also form part of the above-mentioned "sheet metal profiles" of
the module and preferably are included in the prefabricated module,
especially the bottom metal sheet 16.
[0075] FIGS. 10-14, to which reference is now made, illustrate
additional components in embodiments of a building according to the
invention.
[0076] FIG. 10 schematically shows how a volume module 2 as
described above is suspended from six vertical frame columns 70
(four corner columns and two central columns), which form part of
the loadbearing frame of the building. Each frame column 70 is
divided into a number of prefabricated column portions 72, which
preferably have such a length that each column 70 comprises a
column portion 72 for each floor level.
[0077] The column portions 72 are preferably steel beams, such as
rolled steel. They are dimensioned according to vertical forces and
accidental loads. The steel frame is designed so that stabilising
forces can be transferred to stabilising units and foundation.
[0078] As shown in FIGS. 10, 11 and 16, each column portion 72 is
at its lower end prefabricated with a horizontally projecting
bottom flange 74 (40*30 cm in the shown example). Each bottom
flange 74 is provided with four mounting holes 78, and in the
corner columns the bottom flanges 74 are also provided with four
upwardly directed stop lugs 76 (FIG. 16) which cooperate with stop
lugs 38 in the lower corner portions of the modules 2 (FIGS. 24 and
32).
[0079] The frame columns 70 are torsionally rigidly mounted in the
foundation 80 in a suitable manner, for instance by means of
plinths 82 according to FIG. 11, which is a schematic side view of
a building.
[0080] In addition to the frame columns 70, a building according to
the invention can preferably comprise special frame-stabilising
elements.
[0081] FIG. 12, which is a schematic top plan view of a building
according to the invention formed as a 6-module system, shows two
such outer frame-stabilising elements in the form of end walls 90
of the building. They can be made of concrete or steel and extend
the entire height of the building.
[0082] FIG. 14, which is a schematic top plan view of a building
according to the invention formed as a double module system, shows
schematically five frame-stabilising elements in the form of walls
92 of the building which extend the entire height of the
building.
[0083] In such special frame-stabilising elements, other elements
can also be included, such as staircases and/or vertically standing
fa.cedilla.ade panel elements.
[0084] A building according to the embodiment is mounted in the
following manner.
[0085] First the column portions 72 of the first floor level are
mounted in a suitable manner in the foundation 80 (FIG. 11).
[0086] Subsequently, the prefabricated modules 2 of the first floor
level (including the accompanying frame edge beams 50) are lifted
by means of a crane and lowered between the column portions 72 so
that each module 2 is made to rest on the bottom flanges 74 of six
column portions 72. Once the modules 2 are positioned, a neutral
zone NZ (FIGS. 12 and 23) is present between neighbouring modules
2, which neutral zone in the completed building can be bridged in a
convenient manner in roof and/or floor if adjoining modules 2 are
to be interconnected. Specifically, the interconnection of the roof
elements of the modules can effectively contribute to the
stabilisation of the building. The interconnection of the floors of
the modules makes it possible to form larger rooms. Once the
modules 2 are positioned, the frame edge beams 50 are located in a
common plane with the column portions 72, as best seen in FIGS.
23-25.
[0087] It is preferred for the length of the frame edge beams 50 to
be such that they extend with their free beam ends 52 into the
neutral zone NZ and end at a small distance, suitable with regard
to tolerances, from the frame columns 70.
[0088] It should be noted that the modules 2 on the first floor
level are now supported completely at the bottom, whereas the frame
edge beams 50 have not yet been connected with the columns 70.
[0089] It should also be noted that the stop lugs 76 of the bottom
flanges 74 cooperate with the stop lugs 38 of the modules 2,
thereby counteracting horizontal lateral displacement of the
modules 2.
[0090] After having positioned the modules of the first floor
level, the frame edge beams 50 are locked to each other and to the
column portions 72. In the preferred embodiment, this is carried
out by a coupling device 100 (FIGS. 18-20) separate from the column
portions 72, which is used for both interconnections. The coupling
device 100 is in the shown embodiment made of three steel sheets
welded together: one top sheet 102 and two side sheets 104 with
mounting holes 106 and 108/110 respectively.
[0091] As is evident especially from FIGS. 23 and 26, such a
coupling device 100 is arranged on the column portion 72 where two
frame edge beams 50 meet, the top sheet of the coupling device
resting on the top of the column portion 72. By means of the two
side sheets 104, the beam ends 52 of adjoining modules 2 are
connected directly with each other, using bolted joints in the
mounting holes 108 and 53. Since the side sheets 104 extend on
either side of and immediately adjacent to the column portion 72
(FIG. 23), the frame edge beams 50 are also locked laterally
relative to the frame columns 70. Furthermore the coupling device
100 is locked to the column portion 72 using bolted joints in the
mounting holes 110. The frame beams 50 which accompanied the
prefabricated lightweight modules 2 are now included as an
integrated part of the frame construction of the building and can
efficiently transfer forces.
[0092] Having arranged the modules 2 of the first floor level on
the column portions 72, the roof trapezoidal metal sheets 14 of
adjoining modules 2 are interconnected by means of separate panel
elements in the form of trapezoidal metal sheets 15 rotated through
90 degrees (FIG. 23). Thus a larger continuous frame-stabilising
surface is formed on the floor level.
[0093] Subsequent floor levels are then mounted in the same way. In
the frame columns 70 where coupling devices 100 are included, the
column portions 72 on the second floor level will be arranged with
their bottom flanges 74 on top of the coupling device 100 and
connected by bolted joints through the mounting holes 78 and 106.
As an alternative, the coupling device 100 can be integrated into
the column portions 72.
[0094] Different Module Systems
[0095] A module 2 according to the shown embodiment usually has a
floor surface of about 27 m.sup.2, or more if extended. By
consolidating two or more modules, they may be adjusted to optional
layouts, as mentioned above and as indicated in FIG. 1A. The
modules are delivered with or without side walls but are otherwise
usually identical. The bottom flanges 74 of the corner columns 70
are loaded with one to four modules according to the selected
layout. The bottom flanges 74 of the central columns 70 are loaded
with one or two modules according to the selected layout.
[0096] According to the selected layout, stabilisation may be
accomplished in four different ways:
[0097] Single module system
[0098] Double module system
[0099] Multi module system
[0100] 6-module system
[0101] Single Module System
[0102] Singe module system means that each module 2 takes its own
stabilising force and conducts this vertically down to the
foundation 80 through subjacent modules 2. The boards 12 in all
four boundary walls 4, 6 are used as frame-stabilising
surfaces.
[0103] FIG. 15, which corresponds to the vertical section in FIG.
11, shows schematically by means of force arrows how a horizontal
wind force F acting on the second floor level is taken up by the
building and transferred directly vertically to the foundation.
This is in contrast to other embodiments of the invention where the
force can be transferred between horizontally adjoining modules.
This makes it possible to eliminate outer stabilising
fa.cedilla.ade elements, such as concrete walls.
[0104] The wind force F is transferred through the end wall of the
module to the floor and roof board 14, 16. Adjacent to the floor
board 16, the force is then transferred to the longitudinal bottom
beams 20 of this module 2. Adjacent to the roof board 14, the force
is transferred through vertical wall elements 12 down to the bottom
beams 20.
[0105] Thus a horizontal compressive force F4 arises in the right
joint, as indicated in FIG. 15. This horizontal compressive force
F4 is transferred through the stop lugs 38, 50 to the column flange
74 and through the coupling device 100 down to the frame edge beam
50 of the subjacent module 2. The force F4 is now taken up in the
top beam 18 of the subjacent module 2 through two tension rods 54
which are connected to the beam 50 precisely to take up such
horizontal forces. A tensile force F5 thus arises in the right
joint and also in the left joint in FIG. 15.
[0106] In the left joint in FIG. 15, the force is now once again
taken up by the vertical panel element 12 of the module, as
indicated by the force arrow F6. Finally the wind force is
transferred to the foundation 82.
[0107] Double Module System
[0108] Double module system (FIG. 14) means that each module 2
takes its own stabilising force in the same way as the single
system, except that an apartment-separating partition wall 92 is
missing. A double room volume is obtained. The systems of joists
between the modules 2 are connected so that the board effect in the
systems of joists can be utilised. The system can be combined with
a stabilising steel frame.
[0109] In a double module system, only plinths 82 under the
transverse walls 92 are affected by stabilising forces.
[0110] A double module system can be supplemented with a
stabilising steel frame arranged in the partition wall at a
distance of maximum 4 modules. In this case, higher buildings can
be erected.
[0111] Multi Module System
[0112] Multi module system means that the modules 2 are provided
with an outer stabilising wall 90 arranged between each module. The
wall is best made of concrete cast in situ in the form of
semiprefabricated parts, width of the wall about 0.5 m.
[0113] Stabilising forces are transferred through the roof boards
14 interconnected by means of the metal sheets 15--said roof boards
jointly forming a frame-stabilising surface in the roof plane 6 for
each floor level--to outer stabilising constructions and do not
affect the plinth foundation 82.
[0114] 6-Module System
[0115] 6-module system (FIGS. 12 and 13) means that the systems of
roof joists between the modules 2 are connected with the metal
sheets 15, thereby making it possible to use the board effect.
[0116] The stabilising walls 90 or staircases are made of steel or
concrete in the traditional way.
[0117] Stabilising forces are transferred through the roof boards
14 interconnected by means of the metal sheets 15--said roof boards
jointly forming a frame-stabilising surface in the roof plane 6 for
each floor level--to outer stabilising constructions and do not
affect the plinth foundation 82. Thus, horizontal stability is
achieved by the interconnected roof boards and transferred to the
end walls 90 of the building by means of the interconnected frame
edge beams 50. This is contrary to the single module system where
the horizontal stability is achieved through the board effect in
the vertical (gypsum board) walls 12.
[0118] In FIGS. 13 and 14, force arrows indicate schematically how
a horizontal (distributed) wind load F coming sideways is taken up
in the floor boards 14, 15 and is transferred to the mutually
linearly interconnected frame edge beams 50 on each floor level as
tensile forces F1 and compressive forces F2, respectively, which
are transferred horizontally to the end wall elements 90/92 which
transfer the force F3 down to the foundation 80.
[0119] The interconnected frame edge beams also act to keep the
building together.
[0120] The invention, which has been illustrated above by way of an
example, creates a technical solution for stabilisation an open
lightweight building structure, formed as column-supported systems
of joists, and can be implemented so that the modules can be
prefabricated industrially in a system which requires a small
number of mounting operations at the building site.
[0121] The complex of forces that arise in a building that is
subjected to wind forces and inclined forces can by means of the
invention be taken up in joints to be transferred by board effect
to stabilising units.
[0122] According to the invention, this can be realised with
cooperating frame beams, boards, struts and screw joints, which can
all be integrated into the prefabricated lightweight modules and
which at the building site are connected to an outer frame by means
of joints at the top and bottom of the column portions.
* * * * *