U.S. patent application number 10/537921 was filed with the patent office on 2006-11-30 for modular building unit and method of assembly.
Invention is credited to John Window.
Application Number | 20060265971 10/537921 |
Document ID | / |
Family ID | 9948984 |
Filed Date | 2006-11-30 |
United States Patent
Application |
20060265971 |
Kind Code |
A1 |
Window; John |
November 30, 2006 |
Modular building unit and method of assembly
Abstract
The invention provides a modular building unit comprising a
shell formed from side wall lattice frameworks connected together
by cross-beams at floor and ceiling height and end wall lattice
frameworks secured to the ends of the resulting structure. The wall
lattice frameworks are constructed at a first site where each is
formed from an array of mutually parallel spaced structural
uprights made from cold-formed structural steel sections, secured
together by horizontal or diagonal cross-braces also made from
cold-formed structural steel sections. The wall lattice frameworks
are build up into the shell at a second site where each of the
cross-beams, made from a cold-formed structural steel C-section, is
connected to the wall lattice frameworks by being sleeved into or
around lateral spur members extending from the wall lattice
frameworks prior to being welded thereto.
Inventors: |
Window; John;
(Leicestershire, GB) |
Correspondence
Address: |
PIETRAGALLO, BOSICK & GORDON LLP
ONE OXFORD CENTRE, 38TH FLOOR
301 GRANT STREET
PITTSBURGH
PA
15219-6404
US
|
Family ID: |
9948984 |
Appl. No.: |
10/537921 |
Filed: |
December 3, 2003 |
PCT Filed: |
December 3, 2003 |
PCT NO: |
PCT/GB03/05253 |
371 Date: |
February 14, 2006 |
Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04B 1/3483
20130101 |
Class at
Publication: |
052/079.1 |
International
Class: |
E04H 6/00 20060101
E04H006/00; E04H 1/00 20060101 E04H001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 3, 2002 |
GB |
0228172.3 |
Claims
1. A modular building unit comprising a shell formed from side wall
lattice frameworks connected together by cross-beams at floor and
ceiling height and end wall lattice frameworks secured to the ends
of the resulting structure, wherein each of the wall lattice
frameworks comprises an array of mutually parallel spaced
structural uprights made from cold-formed structural steel
sections, secured together by horizontal or diagonal cross-braces
also made from cold-formed structural steel sections, each of the
cross-beams is made from a cold-formed structural steel C-section
and is connected to the wall lattice frameworks by being sleeved
into or around lateral spur members extending from the wall lattice
frameworks prior to being welded thereto, the cross-braces of each
wall lattice framework are centred on a plane that is displaced
outwardly from the internal dimensions of the shell, and internal
cladding on the interior of the shell comprises wall panels
connected to the cross-braces by cold-formed steel resilient bars
each of which has one longitudinal edge portion secured to the
cross-braces and an opposite longitudinal edge portion secured to
the wall panels to hold the wall panels out of contact with the
structural uprights and to define an extended heat path from the
wall panels to the structural uprights through the resilient bars
and through a longitudinally extending portion of each
cross-brace.
2. A modular building unit according to claim 1, wherein the
structural uprights are of C-section and the spur members are
T-shaped or L-shaped each comprising two limbs of which one sits
inside the C-section of the associated structural upright and the
other extends transversely therefrom as a spur to receive an end of
an associated cross-beam.
3. A modular building unit according to claim 2, wherein each limb
of the spur member is made of cold-formed structural steel and has
a general C-section.
4. A modular building unit according to any preceding claim,
wherein each C-section includes one or more swages in the back,
side or front faces of the section.
5. A modular building unit according to any preceding claim,
wherein each C-section includes an inturned flange on one or both
of the front elements of the section.
6. A modular building unit according to any preceding claim,
wherein in each wall panel the cross-braces are welded to the
outsides of the structural uprights.
7. A modular building unit according to any of claims 1 to 5,
wherein in each wall panel the cross-braces pass through slots
formed in the structural uprights.
8. A modular building unit according to claim 7, wherein the slots
are created by stamping apertures in the steel stock from which the
structural uprights are formed, prior to cold-forming the steel
stock into the sectional profile of the structural uprights.
9. A modular building unit according to claim 1, wherein the
structural uprights, the cross-beams and the cross-braces are all
formed from cold-rolled structural steel sections comprising a pair
of arcuate or substantially arcuate opposite side portions each of
which extends in a wholly or substantially smooth arc from a
central slot opening onto the corresponding lateral side and from
the corresponding lateral side onto an arcuate or substantially
arcuate concave portion of a rear wall.
10. A modular building unit according to claim 8, wherein the
cross-braces are connected in the plane of the structural uprights
and extend diagonally from one structural upright to the next.
11. A modular building unit according to claim 8 or claim 9,
wherein selected structural uprights and/or selected cross-beams
are reinforced by including, within one or both of the arcuate or
substantially arcuate opposite side portions, a reinforcing rod or
tube.
12. A modular building unit according to claim 11, wherein the ends
of the reinforcing rods or tubes are provided with connecting means
for connecting them to the reinforcing rods or tubes of adjacent
modules, to connect together the modules.
13. A modular building unit according to any preceding claim,
wherein additional floor panel thickness external panels are
secured over the top of the shell.
14. A modular building unit according to any preceding claim,
wherein each of the connections between the structural uprights and
the horizontal cross-braces and each of the connections between the
spur members and the structural uprights and the cross-beams
incorporates at least one weld that is a spot weld, a seam weld or
a plug weld.
15. A modular building unit according to any preceding claim,
wherein door and window final fittings, together with electrical
and plumbing connections, are incorporated into the modular
building unit before that unit is assembled with others as a
building.
16. A method of fabricating a modular building unit according to
any preceding claim, comprising: (a) creating a shell by: (i)
fabricating the wall lattice frameworks each comprising: an array
of mutually parallel spaced structural uprights secured together by
horizontal or diagonal cross-braces, both the structural uprights
and the cross-braces being made from cold-formed structural steel
sections, with the cross-braces being centred on a plane that is
displaced outwardly from the internal dimensions of the shell, and
a row of floor level spur members and a row of ceiling level spur
members extending laterally from the structural uprights of each
wall lattice framework; (ii) joining together the wall lattice
frameworks to form the shell by sleeving the cross-beams of
cold-formed structural steel C-section into or around the spur
members and then welding the cross-beams to the spur members; and
(iii) securing the end wall lattice frameworks to opposite ends of
the shell so formed; and (b) lining the shell by securing the wall
panels to the cross-braces by securing one longitudinal edge
portion of each of an array of cold-formed steel resilient bars to
the cross-braces and an opposite longitudinal edge portion of each
of the resilient bars to the wall panels to hold the wall panels
out of contact with the structural uprights and to define an
extended heat path from the wall panels to the structural uprights
through the resilient bars and through a longitudinally extending
portion of each cross-brace.
17. A method according to claim 12, wherein the side and end wall
lattice frameworks are made and assembled at a first manufacturing
site; those assembled frameworks are transported to a second
manufacturing site; the wall lattice frameworks are assembled with
the cross-beams to form the shell at the second manufacturing site;
and the shell is lined and fitted-out at the second manufacturing
site.
Description
[0001] The invention relates to modular building units for use in
the construction of largely prefabricated offices, hotels and
apartment blocks, and buildings of a similar general nature. Such
modular building units are box-like structures which can be
manufactured and fitted-out off-site and then transported to a
construction site for final assembly to form the internal rooms of
a building.
BACKGROUND ART
[0002] Particularly in the construction of hotels, apartments and
student accommodation it is known to construct the buildings from
lightweight building modules each of which is a skeletal steel
shell formed from lightweight structural steel sections welded into
a box-like structure and lined with boarding such as plasterboard,
plywood or oriented strand board (OSB). Each building module is
made initially as such a lined shell, and is then fitted-out to the
desired standard of internal decoration in a factory before being
transported to the final building site for incorporation into a
building.
[0003] GB-A-2334045 discloses one method of construction of such a
building module. A number of rectangular or otherwise identically
shaped frame members are formed and aligned in mutually spaced
parallel relationship as the ribs of the final skeletal shell. Then
they are connected together by multiple cross-braces which lie on
the inside of the resulting shell. Wall panels are secured to the
cross-braces. Floor and ceiling panels are added, as are end
panels, and the module is finished to its final standard of
internal decoration.
[0004] One inevitable characteristic of the module of GB-A-2334045
is that the entire module is made and fitted-out in a single
factory. The initial fabrication step of setting out the pre-formed
row of rectangular frame members and joining them together with the
horizontal cross-braces creates a skeletal steel box-like
structure. Once this skeleton is welded into its final box-like
shape or shell the transportation of that shell becomes a major
expense, with a separate lorry or low-loader being needed to move
each such skeletal shell out of the factory. Therefore the shells
are lined and fitted out in the same premises which may be a
considerable distance from the site of the final building to be
erected. The completely fitted-out modules are then transported,
generally by road, to the final building site for erection of the
hotel or apartment block to be built. This carries with it
considerable potential transport costs.
[0005] Another characteristic of the module of GB-A-2334045 is that
a direct thermal path is provided from the internal panelling to
the frame members through the cross-braces. A fire in the finished
building therefore has a relatively short heat path before it
causes distortion of the ribs or frame members which are the
structural uprights of the finished building. This is a major
concern because the steel of the frame members and cross-braces is
lightweight steel framing and can readily distort in the event of
thermal overload. The maximum height of a building made from
modules in accordance with GB-A-2334045 is therefore a relatively
small number of storeys, typically about four or five.
[0006] It is an object of the invention to provide a building
module and a method of building using such modules which both
reduces cost and improves the fire resistance of the building as
compared with the use of similar grade materials in the known
modular building methods. By improving the fire resistance of each
module the invention permits the erection of higher rise blocks of
rooms using the building modules of the invention.
The Invention
[0007] The invention comprises a modular building unit as specified
in claims 1 to 11 herein, and a method of fabricating a modular
building unit as specified in claim 12 herein.
[0008] The building modules according to the invention can be
stacked in a horizontal and vertical array using edge location
means as described and claimed in copending Patent Application No
W068005 filed herewith, and linked together horizontally and
vertically as described and claimed in W068006 filed herewith, to
form buildings 20 or more storeys high. If desired the outside of
such buildings can be cross-braced using diagonal structural
members which may themselves be made from lightweight cold-formed
steel section. Such cross-braces are known per se. That may however
be unnecessary if the cross-braces are located diagonally rather
than horizontally.
[0009] The lightweight structural steel sections used as the
structural uprights in the modular building units of the invention
have excellent tensile stress resistance but relatively poor
compression resistance. Additional tensile stress resistance may
however be provided by incorporating a rod or tube or cable within
selected ones of the structural uprights. If rods or tubes are
used, then each preferably extends the full height of the wall
lattice framework, which is the height of one full storey of the
erected building, and preferably terminates at each of its ends
with means for connecting that rod or tube to aligned rods or tubes
of the vertically adjacent storeys. That effectively ties together
the successive storeys of the finished building in the vertical
direction. If desired similar rod, tube or cable reinforcement can
extend horizontally from end to end or side to side of the building
module through the wall lattice framework or through the
cross-beams, for tying together adjacent modules of the erected
building in the horizontal plane.
[0010] Particularly for the construction of buildings more Man 20
storeys high, or buildings that are susceptible to lateral shear
forces caused by side winds, the external walls of the buildings
are preferably reinforced by highly compression-resistant columns
either included within the wall thickness of the pre-formed
rectangular frame units or secured to the outsides of the
individual modules or stacks of modules.
[0011] A preferred form of compression-resistant column is one
which comprises a hollow tubular steel section filled with
concrete, preferably with concrete that is reinforced with steel
rods. The steel section may be hot-formed, for example as
rectangular or circular section tubular steel stock, or may be made
from lightweight cold-formed steel similar to the steel used in the
remainder of the building module. Individual compression-resistant
columns may be the height of one single modular building unit or
may be the height of two or more storeys in the final building. If
the former then the compression-resistant columns may be
incorporated into the individual wall lattice frameworks. Otherwise
they may be attached to the outside of the assembled building
module or to the outside of the assembled building. If desired the
compression-resistant columns may be pre-cast and optionally
reinforced concrete columns each of which is received in a void
established between two or more mutually spaced parallel structural
uprights, and the wall lattice framework built around those
columns.
[0012] The invention also provides a method of fabricating the
modular building unit of the invention when divided in a
cost-effective manner between two manufacturing sites as specified
in claim 17 herein. The side and end wall lattice frameworks are
made and assembled at the first site, and also at the first site it
will generally be convenient to manufacture all other cold-formed
metalwork, including the cross-beams and any other formed metalwork
to be used in the final assembly process. This means that all of
the apparatus for cold-forming the structural members from
lightweight steel can be provided at that first site. Also, the
assembly of the wall lattice frameworks, which is a skilled
operation requiring a high degree of precision, is suitably carried
out at that first site. The assembly of the wall lattice frameworks
is generally achieved by placing the individual structural formed
steel members in an assembly jig, and then welding the components
together by spot welding, seam welding or plug welding. The end
product of that first manufacturing site is therefore a series of
essentially flat wall lattice frameworks and optionally a series of
essentially linear structural members such as the cross-beams, all
of which can be loaded flat onto a lorry or railway truck, enabling
the components of several modular building units to be loaded
together onto a single lorry or truck. From the first site, those
components are then transported to the second manufacturing site,
which would typically be a regional site relatively close to the
area in which the final building is to be erected from a number of
assembled modules. At the second site, the wall lattice frameworks
are assembled with the cross-beams to form the shell, and the shell
is lined and fitted-out. Movement of the shell from the second site
does require a single lorry or low-loader to transport each
individual building module to the final building site for erection
into a building, but by strategic use of regional assembly sites,
the entire operation can be made much more economical than the
assembly method of GB-A-2334045 which requires the assembled units
to be transported from a single manufacturing and assembly site
where all of the precision work as well as the non-precision work
of assembly and fitting-out is performed.
[0013] Preferably both the structural uprights and the cross-beams
are of C-section. As is well known, such a section comprises a back
face, two side faces and two front faces. Added strength can be
provided by including one or more swages in one or more of the
back, side and front faces, and the strength can if desired be
further increased by including an inturned flange on one or both of
the front faces. Even greater strength can be created by sleeving
together two C-sections, one of which is swaged and the other of
which is unswaged or swaged in the opposite direction, so that the
assembly of the two C-sections creates a box structure with one or
more continuous box channels running longitudinally of the final
composite section.
[0014] The spur members which extend from the wall lattice
frameworks may be T-shaped in plan view, each comprising two limbs
of which one sits inside the C-section of the associated structural
upright and the other extends transversely therefrom as a spur to
receive an end of an associated cross-beam which is sleeved into or
around that spur prior to being welded thereto.
[0015] The structural uprights, the cross beams and even the
cross-braces are however preferably structural building elements
formed from cold-rolled steel with sections as described and
claimed in copending Patent Application No W068007 and as specified
in claim 9 herein. Such sections are based generally on a C-section
profile but with the maximum use of large diameter curves in place
of the conventional flat faces. These sections are referred to
herein as multi-curve C-section profiles. W068007 also discloses
connectors suitable for joining together such multi-curve C-section
profiled building elements into a lattice framework such as would
be used according to this invention. In a typical lattice framework
using only multi-curve C-section profiled structural uprights,
cross-beams and cross-braces, the cross-braces would be in short
lengths, each spanning only a single gap between adjacent
structural uprights and connected to the structural uprights by
T-connectors or K-connectors according to W068007. Alternatively
the cross-braces could be wider than the structural uprights, with
the latter passing completely through oval slots stamped into the
cross-braces during fabrication. Welds would be needed to secure
the joints and make the lattice framework rigid.
[0016] The cold-formed steel resilient bars which connect the wall
panels to the cross-braces are preferably Z-section profiles of
which both formed angles are obtuse. One longitudinal edge portion
of such a Z-section is a flange which is secured to
thecross-braces, preferably down a vertical line of fixing points
midway between adjacent structural uprights. The wall panels of the
internal cladding are secured to the opposite longitudinal edge
portion of the Z-section, which is also formed as an edge flange.
The fixing means for the wall panels to the resilient bars may be
any convenient mounting method, such as self-tapping screws. The
two obtuse angles of the preferred Z-section shape provides
resilience to the mounting of the internal cladding on the interior
of the shell, that resilience being sufficient to reduce the sound
transmission between the wall panels and the shell. Nowhere do the
wall panels contact the structural uprights or the cross-braces,
because they are held clear by the resilient bars. There is
therefore no direct sound transmission from the wall panels to the
structural uprights and, much more importantly, an extended heat
path is provided between the wall panels and the structural
uprights, passing first through the resilient bars to the
cross-braces and then longitudinally of the cross-braces before
they in turn are connected to the structural uprights. This
extended heat path provides excellent thermal protection for the
structural uprights in the event of a fire within the modular
building unit. Preferably the wall panels used as internal cladding
on the interior of the shell comprise two thicknesses of plaster
board for even greater acoustic and thermal insulation.
[0017] The internal cladding to the interior of the shell also
comprises floor and ceiling panels. Preferably additional external
panels of floor panel thickness and strength are applied over the
top of the shell. The latter means that when the modular building
units are being assembled into a building, those additional
external panels applied over the top of the shell can take the
weight of the workforce assembling the building, without the need
for scaffolding or walking boards.
DRAWINGS
[0018] FIG. 1 is a schematic illustrating the drawing convention of
FIGS. 2a to 2e;
[0019] FIGS. 2a and 2b are elevations of the skeletal structures of
two side wall lattice frameworks of a modular building unit
according to the invention;
[0020] FIGS. 2c and 2d are elevations of the skeletal structures of
two end wall lattice frameworks of the modular building unit;
[0021] FIG. 2e is a plan view of the floor and ceiling joists of
the modular building unit;
[0022] FIGS. 3 to 8 are sections taken along the sectional planes
3-3 to 8-8 respectively of FIGS. 2c, 2d and 2b;
[0023] FIGS. 9 to 12 are enlarged sectional details of the zones
indicated 9 to 12 respectively of FIG. 2e;
[0024] FIG. 13 is a plan view of a piece of sheet steel blank which
is folded to fabricate a first part of a spur member for securing
the cross-beams to the wall lattice frameworks, with the intended
fold lines being shown in broken line;
[0025] FIG. 14 is a perspective view of the blank of FIG. 13 folded
into its final shape;
[0026] FIG. 15 is a perspective view corresponding to FIG. 14 but
with a reinforcing plate added;
[0027] FIG. 16 is a perspective view corresponding to FIG. 15 but
with two vertical C-channels added to develop a generally T-shaped
plan view outline to the spur member;
[0028] FIG. 17 is a perspective view of an alternative design of
spur member;
[0029] FIGS. 18a to 18j are alternative C-sections that can be used
for the structural uprights;
[0030] FIGS. 18k to 18n are alternative multi-curve C-section
profiles as disclosed in W068007;
[0031] FIG. 19 illustrates the section of across-brace for use with
the C-sections of FIGS. 18a to 18j;
[0032] FIG. 20 illustrates the section of a steel resilient bar to
support the wall panels and hold them away from the structural
uprights;
[0033] FIG. 21 is a vertical section through a
compression-resistant column for use in the erection of a tall
building from modules according to the invention;
[0034] FIG. 22 is a horizontal section through two structural
uprights straddling a pre-cast reinforced concrete
compression-resistant column to be used as an alternative to that
of FIG. 21; and
[0035] FIG. 23 is a side elevation of a preferred lattice framework
using structural uprights and cross-braces with the section shown
in FIG. 18k.
[0036] Referring first to FIGS. 1 and 2, the modular building unit
of the invention is made by first constructing two side wall
lattice frameworks as seen in FIGS. 2a and 2b, and two end wall
lattice frameworks as seen in FIGS. 2c and 2d. Each such lattice
framework comprises an array of mutually parallel spaced structural
uprights 20 secured together by horizontal cross-braces 22. The
structural uprights 20 are cold-formed lightweight structural steel
C-sections which can have any of the general profiles shown in
FIGS. 18a to 18j. In FIGS. 18a to 18h, the C-section is shown
either unswaged (FIG. 18a) or with one or more swages 23 formed in
the back 20a, side 20b or front 20c faces of the section. FIGS.
18e, 18f, 18g and 18h show how the C-section includes an inturned
flange 24 on each of the front faces 20c of the section. FIGS. 18i
and 18j show how the C-section can be further reinforced by the
inclusion of additional C-sections to create closed box sections
for additional strength.
[0037] For structural uprights shaped as in FIGS. 18a to 18j, the
cross-braces 22 are of top hat section, as shown in FIG. 19, and
are spot welded or plug welded to the rear of the structural
uprights 20 as viewed in FIGS. 2a to 2d. For increased rigidity,
short spacer sections 26 of similar section can be positioned
between adjacent structural uprights 20, and spot welded to the
cross-braces 22.
[0038] FIGS. 18k to 18n show how the structural uprights may have a
multi-curve C-section profile as described and claimed in W068007,
in which case the cross-braces and cross-beams may also have any of
the same general profiles.
[0039] Extending vertically down each side and end wall lattice
structure and secured to the cross-braces 22 either directly or
through the spacer members 26 are a vertical array of cold-formed
steel resilient bars 28 each of which has a Z-section with obtuse
angles as illustrated in FIG. 20.
[0040] Extending laterally from each structural upright 20 is a
pair of spur members 30 and 32, as shown in FIGS. 8 and 7
respectively. The spur members 32 are of different sizes to
correspond to the sizes of the corresponding cross-beams at floor
and ceiling height, but each is constructed as shown in FIGS. 13 to
16. FIG. 13 shows a blank 34 of sheet steel which is bent along the
broken lines into the general conformation shown in FIG. 14. That
shape is then fixed against distortion by spot welding into
position a reinforcing plate 36 as shown in FIG. 15, the lines of
the spot welds being shown by a rows of crosses in FIG. 15. Finally
a pair of vertical C-section channels are spot welded along the
vertical edge as shown in FIG. 16, to create a general plan view
which is T-shaped. The cross bar of the T, defined by the two
C-sections 38, is received in the recesses of the structural
uprights 20 in the same positions as the reinforcing C-sections 25
which are shown in FIGS. 18i and 18j, leaving the stem of the T
jutting out transversely as a spur 30 or 32. Onto or into each
projecting spur member 30, 32 is sleeved a cross-beam 40 of the
floor or roof of the module, as illustrated in FIG. 2e. Reinforcing
cross-members 42 may be welded in place as required, for greater
structural rigidity.
[0041] FIG. 17 shows an alternative construction for the spur
members 30,32. A single piece of C-section channel 44 is provided
with a cap 42 of top hat section, the two being welded together
with spot welding or plug welding. The top hat section 42 forms the
bar of the resulting T-section spur member, and is received in the
C-section of the structural uprights. The C-section 40 projects as
the spur.
[0042] If the structural uprights and cross-beams have the profiles
of FIGS. 18k to 18n, the spur members are connected as described in
my copending Patent Applkication No W068007.
[0043] Once the skeletal shell has been assembled as described
above, it is lined for example with plasterboard 44 as shown in
FIGS. 3 and 4. Preferably two sheets of plasterboard 44 are used,
on both the walls and the ceiling. Flooring 46 is also added (see
FIG. 4) and may be for example plywood, chipboard or OSB
panels.
[0044] The connection of the plasterboard cladding 44 to the
skeletal shell is through the steel resilient bars 28, which are
sized such as to hold the plasterboard wall panels 44 clear of the
structural uprights 20 as shown in FIGS. 3 and 4. The spacing is
there illustrated as being extremely small, but even a small
spacing does establish acoustic insulation together with a long and
convoluted heat path from the plasterboard wall panels 44 to the
structural uprights 20, as any heat resulting, for example, from an
internal fire in the finished module has to pass laterally across
the resilient bars 28 to the cross-braces 22, and then
longitudinally along those cross-braces 22 to the structural
uprights 20.
[0045] After the internal cladding has been secured in position as
described, the building module can be completely fitted out in a
factory before being transported to a building site where it is
lifted into position alongside or on top of other similar modules,
to create the finished building. Door and window final fittings,
together with electrical and plumbing connections, are incorporated
into each modular building unit before the unit is assembled with
others as a building, then all that is necessary is to connect in
those services and finish the building with a final facing skin
which could be of brick or timber, to complete a fully internally
decorated building.
[0046] Other details of the structure are apparent from FIGS. 9 to
12. Elements of a doorframe 50 are shown in FIG. 9, and comprise
studs consisting of an LC-section with an insert SC-section. FIG.
10 shows a detail of corner studding. Structural uprights 52 are
provided at the corners, each consisting of an LC-section with an
inset SC-section. FIGS. 11 and 12 show how a greater structural
strength is obtained on an outside wall by creating the outside end
wall as a sandwich of a first array of structural uprights 20
connected together by cross-braces 22, and attached to the outside
of that a second array of structural uprights 20' connected
together with cross-braces 22'. Externally, the module is completed
with a bottom angle 54 and a top angle 56 to finish the corners,
and internally with a bottom angle 58 and a top angle 60, all as
shown in FIGS. 3 and 4.
[0047] In practice, the side and end wall lattice frameworks of
FIGS. 2a to 2d are created on site in a first factory. If desired
the spur members may be welded into position at that initial
assembly site; or alternatively they may be provided to be slotted
into place and welded into position at a second, less skilled,
assembly site provided that the side and end wall lattice
frameworks are provided with adequate location means to enable
those spur members to be placed into a fully located end position
before being welded in place. The essentially flat sections are
then transported, by road or by rail, to that second site which is
a regional site where they are built up into the finished module.
First of all the two side wall latticed frameworks are connected
one to the other by means of the cross-beams 30 and 32 at floor and
ceiling height. Then the end wall lattice frameworks are presented
up and welded into position. Next, the internal cladding is secured
in position and preferably an additional sheet of external roof
cladding is fixed over the roof of the module. The roof cladding
may for example be OSB board of full flooring strength. Finally the
interior of the module is painted and decorated to a final desired
standard, including if necessary carpets and general fixtures such
as fixed cupboards, before the finished module is moved from the
second assembly site to the final building site.
[0048] Stacking of adjacent modules, and securing them together, is
as described and claimed in my other three Patent Applications,
W068005, W068006 and W068007, filed herewith. The modules as
already described may be stacked and assembled into buildings up to
twenty storeys high However to construct taller buildings, or
buildings which are subject to severe lateral stresses by virtue of
either their location in a windy environment or their tall narrow
geometry, it may be desirable to strengthen the outside walls using
diagonal cross-braces or compression-resistant columns. The
compression-resistant columns may be built into the walls of the
pre-formed rectangular frame units, or may be secured to the
outside of the individual modules or stacks of modules. In the
former case the structural uprights would be made the same height
as the individual walls of the building units; in the latter case
they might be the height of a single storey of the building or the
height of two or more storeys. FIG. 21 illustrates one form of
compression-resistant column made by filling a tubular metal column
62 with concrete 63. The steel upright 62 may be formed from
lightweight cold-formed steel section. The concrete fill 63 is
formed into a domed nib 64 at the top, with a corresponding domed
indent 65 at the bottom. When the resulting columns are placed one
above the other to provide outer reinforcement for the finished
building, then the nib 64 of each column engages in the
corresponding recess 65 of the corresponding column of the storey
immediately above, for positive location. FIG. 21 also shows the
provision of steel reinforcing bars 66 which add more structural
strength to the compression resistant columns. If the columns are
not built into the walls of the individual modules, then they may
be secured to the outside walls, for example by welding.
[0049] FIG. 22 shows how the compression-resistant columns may be
built into the wall lattice framework. A pre-cast column 71 of
reinforced concrete is provided, to extend the height of the wall
lattice framework. The top and bottom may be provided with a nib
and indent corresponding to those numbered 64 and 65 in FIG. 21.
The column 70 is shaped to lie between two structural uprights 20
each having the profile shown in FIG. 18n, and steel straps 71 are
welded to the outside of the uprights 20 to hold the assembly
together. That reinforced composite structural upright may then be
assembled into a wall lattice framework as described elsewhere in
this specification.
[0050] FIG. 23 illustrates a highly preferred wall lattice
framework for incorporation into a building module according to the
invention. The structural uprights 20 and cross-braces 22 have the
profile of any of FIGS. 18k to 18n. The cross-braces 22 are
connected diagonally, in a triangulation pattern for maximum
strength. Each cross-brace 22 is connected to its associated
structural uprights 20 and to the adjacent cross-brace 22 by a pair
of pressed steel plates 72 positioned one on the outsid eand one on
the inside of the wall lattice framework and welded to the uprights
20 and cross-braces 22. Chain-dotted lines 73 indicate the lines of
connection of the steel resilient bars 28.
[0051] The individual building modules made up as described need
not be rectangular in plan view. Any plan shape can be
accommodated. Trapezoidal modules can be places together to create
either straight or curved buildings. The modules can include
features such as balconies to lie on the outside wall of the
finished building. The walls do not even have to be straight, as it
can be appreciated from FIG. 23 that a curved wall can easily be
constructed, for use according to this invention, from the
multi-curve C-section profiled structural uprights and cross-braces
of my Patent Application No W068007.
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