Buildings
A modular building system for constructing a building comprises a frame for detachably mounting modules providing rooms and modules providing services to the rooms. The service modules are located between room modules and the modules can be inserted in and removed from the frame without compromising the integrity of the building
This invention relates to improvements in or relating to buildings formed from prefabricated modules and to a building system for constructing buildings employing such pre-fabricated modules.
BACKGROUND OF THE INVENTIONIt is known to construct buildings of prefabricated modules. Typically, box-shaped modules containing rooms of the buildings are prefabricated and tested off-site and then transported to the building site where they are assembled to form the modular building. This eliminates a large proportion of on-site building and increases the speed of construction of the building.
During construction, the modules are lifted into place by crane with services (such as air conditioning, gas, electricity and water supplies) constructed and connected with the modules after the modules are installed. A roof and external cladding are constructed around the modules to form a weatherproof exterior of the building. In such a construction, recovering the modules causes extensive damage to the roof, cladding and services or is not possible at all.
According to a first aspect of the invention there is provided a building comprising a plurality of prefabricated modules, wherein each module is removable from the building independently of the other modules and without compromising the integrity of the building.
In this way, the prefabricated modules can be removed and replaced, allowing the building to be adapted to changing user requirements.
The building may comprise a weatherproof exterior surrounding the modules and each module is removable from the building without damaging the weatherproof exterior.
The building may comprise a frame in which the modules are removably mounted. The frame may be made of any suitable material, however in a preferred embodiment the frame is made of steel.
The frame may provide support for external cladding and roofing of the building forming the weatherproof exterior. The external cladding may be removable to allow access to the modules for removal and insertion of the modules. Accordingly, the necessity for tradesmen to enter the building is greatly reduced because tradesmen can gain access to the modules from the exterior of the building by removing the appropriate cladding.
In one arrangement, the removable cladding is a plurality of panels mounted on the outside of the frame and arranged to be detachable from the frame to allow access to modules for removal and re-attachable to the frame once the module has been removed/replaced.
In an alternative arrangement, the removable cladding is a plurality of weather tight doors permanently mounted on the frame and movable from a closed position concealing the modules to an open position allowing access to modules for removal. The doors may be pivotally mounted to the frame and may be opened/closed by any suitable means, for example hydraulic, pneumatic or electric actuators may be employed.
Preferably, means is provided to facilitate insertion and removal of the modules into and from the frame. The means may be a mechanism, which allows the modules to be slid into and from the frame. This aids quicker and safer construction of the building and replacement of modules.
The mechanism may comprise pairs of horizontal skids on the frame and/or modules, each pair of skids arranged to allow a module to slide across the frame to guide and support the modules during insertion and removal.
Alternatively or additionally, the mechanism may comprise guides mounted on the frame that have formations that inter-engage with runners on the module to allow sliding movement of the modules relative to the frame during insertion and removal of the modules. The guides may be mounted on sides of the frame and the runners on outer sidewalls of the modules. In this way, the modules are located in the frame both horizontally and vertically by inter-engagement of the runners with the guides.
Means may be provided to assist insertion/removal of the modules. For example a rack and pinion mechanism, a hydraulic, pneumatic or electric ram or other suitable powered mechanism.
The building may comprise means for supplying services to the modules. The service supply means may be one or more of electricity supply, water supply, gas or other fuel supply, medical gas supply, air conditioning, connections to monitoring means, such as means for monitoring air pressure, decontamination means or the like.
Preferably, prefabricated service modules are provided housing the service supplying means. The service modules may be located in between removable modules. This is desirable as the service supply means can be tested at the factory before assembly and supplied to the building site ready-made increasing the speed of construction of the building.
Each (removable) module may be detachably connected to the services such that the module can be disconnected from the services for removal from the building without damaging the service supply and disrupting the supply of services to other modules. As a result, removal of a module does not cause or only results in minimal downtime for other modules of the building.
The removable modules are suitable for forming part of a decontaminated area of the building as tradesmen can access the modules for removal with minimal interference with the clean area.
The building may be a permanent or semi-permanent building.
According to a second aspect of the invention there is provided a prefabricated module for assembly into a building according to the first aspect of the invention.
According to a third aspect of the invention there is provided a system for detachably securing a building according to the first aspect of the invention to a load bearing foundation.
According to a fourth aspect of the invention there is provided a method of constructing a building comprising prefabricating a plurality of modules, and assembling the modules together to form a building, wherein each module is assembled to be removable from the building independently from the other modules and without compromising the integrity of the building.
According to a fifth aspect of the invention there is provided a method of renovating a building formed of a plurality of modules, each module housing one or more rooms, comprising removing one or more of the modules from the building and replacing the removed module or modules with one or more further prefabricated modules.
According to a sixth aspect of the invention there is provided a method of constructing a building comprising prefabricating a plurality of modules housing one or more rooms, prefabricating a plurality of service modules housing a predetermined arrangement of connections for supplying services to the rooms when assembled in a building and assembling the modules together to form a building with services supplied to the rooms via the connections in the service modules.
According to a seventh aspect of the invention there is provided a method of installing a building comprising providing a foundation structure and detachably attaching a frame for the building to the foundation structure.
Embodiments of the invention will now be described, by example only, with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring first to
The building 1 comprises an outer ring 6 of modules 2 that are removable from the building, as explained later herein. These removable modules 2, together with service modules 3 and corners 5 form a “clean” area that is maintained free from contamination. Such an area may be desirable in research centres and hospitals where it is important to prevent contamination of experiments/patients.
The building 1 also comprises an inner ring 7 of fixed/permanent modules 4, surrounding courtyard 8, that form a “dirty” area in which people can remain without concern for maintaining a decontaminated environment. Such an area may contain toilets, write-up areas for researchers, a canteen, etc.
The “clean” area 6 and “dirty” area 7 are separated by permanent corridors 8 and 9. Access from the “dirty” area to the “clean” area will be carefully controlled in order that the “clean” area is not contaminated.
Stairs and/or lifts are provided in the corners 5 of the building 1. These corners 5 may additionally or alternatively comprise pipelines, air ducts, cables etc for the supply of services to the building 1 with access points to enable servicing of equipment in voids. The corners 5 may comprise modules that slide in and may be interchangeable for adapting the layout to any desired requirements.
With particular reference to
The building 1 comprises a steel frame 11 for mounting of the modules 2 and 3. The frame 11 has vertical columns 12 and horizontal beams or panels 13 forming a grid having spaces 19 for receiving modules 2 and 3.
Each module 2 is a rectangular box comprising four walls, a floor and a ceiling defining one or more rooms accessible by a person. It will be understood however that the modules 2 can be of other shapes. In
Each module 2 is provided with sliding mechanisms for the floor and side walls of the module 2 to support and ease movement of the module 2 into and out from the frame 11.
The sliding mechanism for the floor comprises a pair of laterally spaced units 15,16 on the underside of the module. Each unit 15,16 is similar and may comprise horizontal skids 15a (
The sliding mechanism for the sidewalls comprises a pair of laterally spaced units 17,18 on the outside of the module. In this embodiment, the units 17,18 are located approximately at the mid-point of the sidewalls. Each unit 17,18 is similar and may comprise horizontal runners 20 mounted on the module 2 and horizontal guides 21 mounted on the vertical columns 12 (
In a modification (not shown), the sliding mechanism on the sidewalls of the modules 2 may be omitted. Alternatively, the sliding mechanism on the underside of the modules 2 may be omitted.
Each module 2 is positioned in space 19 to fit against permanent wall 10 of corridor 9 in an airtight manner maintaining clean and pressure regimes to the building 1. A door aperture (not shown) of the module 2 and door aperture of the corridor (not shown) are aligned for access to the module 2 from the corridor 9 and maintained airtight by means of seals, gaskets, covers, mouldings or specialist products.
Service modules 3 are connected with the frame 11 below the horizontal beams/panels 13 to lie between storeys. The service modules 3 are rectangular boxes with walkways that house connections, such as pipe work, electrical cables, air ducts, etc, for the supply of services to the modules 2. In this embodiment, the service modules 3 are of reduced height compared with the room modules 2.
The services can be gas for heating, gas for medical or research purposes, water, electricity, a fire alarm system, air conditioning, electrical connections to environmental monitoring systems, air leakage detection, light controls etc, pipe work supplying decontamination chemicals or the like. During construction, the prefabricated modules 3 are brought to the building site and placed/slid into position in the frame 11 by means of a sliding mechanism employing units 15,16 and/or 17,18 similar to those already described for the modules 2.
Modules 2 comprise flexible connectors (not shown) detachably fitted with the connections of the service modules 3 as desired to supply the services to modules 2.
The frame 11 also provides support for a roof (not shown) and cladding that surround the modules 2, 3 and 4 to conceal the modules from view and form a weatherproof exterior of the building 1. The roof may also be modular and interchangeable.
The cladding 24 is formed of a series of panels 25 that are detachably mounted on the frame 11. Detaching these panels 25 provides access to the modules 2 for removal and the panels 25 can be reattached to the frame 11 once the module 2 has been removed.
In an alternative embodiment (not shown), the cladding is formed of a series of large doors that are pivotally mounted on the frame 11. In a closed position, the doors enclose the modules 2,3,4 to provide a weatherproof exterior and are movable to an open position allowing access to the modules 2 for removal.
The building 1 is constructed by prefabricating and testing modules 2,3,4 in a factory remote from the building site. The modules 2,3,4 are then transported to the building site where they are assembled into frame 11, typically by crane, to form the building 1. An airtight seal is completed between the modules 2 and permanent wall 10 of corridor 9. The cladding and roofing are constructed as the modules 2,3,4 are assembled into the frame 11.
After construction, if it is desired to remove and replace one or more of the modules 2, panels 25 are detached from frame 11 to provide access to the modules 2 to be removed. The modules 2 are disconnected from services and slid from the frame 11. A replacement module 2 can then be slid into place and connected with the services provided by the service module 3. The replacement module 2 fits against the permanent wall 10 with airtight seals formed to maintain the integrity of the “clean” area 7. Finally, the panel 25 can be reattached to conceal the modules 2 and make good the weatherproof exterior.
It is envisaged that spare modules 2 will be prefabricated at the factory in readiness for replacing modules 2 currently in use. The modules 2 will be prefabricated initially as a basic shell. On request from a customer, the basic shell can be adapted to the specific requirements of the customer and tested at the factory. The adapted module is then transported to the building site where it replaces an existing module of the building, by the method as described above. In this way, a quick turnaround is provided between the customer requesting and receiving a new module.
Referring now to
In this second embodiment, the building includes modules 102 are open on one or both sides so that a room can be formed by inserting two or more modules 102a,b,c into adjoining spaces 119 of the frame 111 with the open sides of the modules 102 facing each other.
The gap in the floor, wall, and ceiling between the modules 102a,b,c is filled by inserting a closer member 150 (
Thus, the closer member for the gap in the floor may have a load supporting faceplate that matches the floor surfaces of the modules 102 and can withstand being trodden on. The closer member for the gap in the wall and/or ceiling may have a faceplate of plasterboard that matches the finish of the walls and/or ceiling of the modules 102.
The closer member 150 is provided on the rear of the face plate with laterally spaced seals/gaskets 150b connected by a tensioning mechanism 150c to maintain sealing engagement around the peripheral edges of the open sides of the adjacent modules. The faceplate 150a may also include one or more removable access panels 150d for obtaining entry to the gap between the modules.
In this embodiment, the units 117, 118 of the sidewall sliding mechanism are raised so as not interfere with free movement between adjacent modules 102a,b,c and are located between the vertical columns 112 of the frame 111 and the sides of the modules 102 at or near ceiling height. The modules 102a,b,c are provided with temporary supports 151 on the open sides to assist in maintaining the required spacing and alignment during installation of the modules 102a,b,c. The temporary supports 151 are removable when the modules 102a,b,c are installed.
Adjacent service modules (not shown) inserted in the service void above each module 102 may be interconnected in similar manner. The number and arrangement of the interconnected modules 102, 103 may be varied according to the design of the building for any particular application. In other respects, the construction of this building is similar to the first embodiment and will be understood from the description already provided.
Referring now to
In this third embodiment, the modules 202 are shown either side of a corridor module 260 with service modules 203 above. The floor, walls and ceiling of the corridor module 260 are sealed relative to the adjacent modules 202.203 where required by means of closer members 250 (
Referring now to
In this embodiment, the frame 311 is anchored by releasably securing at least some of the vertical columns 312 to a foundation beam 380 sunk into the ground on which the building is to be erected. The frame 311 may support the drainage waste systems (not shown). Typically, the columns at the corners of the frame are secured and, depending on the size of the building some or all of the columns between the corners may also be secured. The number and position of the columns that are to be secured may be varied according to the requirements for a particular application.
Each column 312 is secured in similar manner by connecting the lower end of the column 312 to a steel I-beam 381 bolted or welded to a steel connector plate 382. The connector plate 382 is connected to a socket 383 cast into the beam 380 via a support member 384 that allows the height of the connector plate 382 to be adjusted for levelling the frame 311. A collet 385 mounted on the support member 384 is operable to lock the connector plate 382 at the desired adjusted position. When it is desired to remove the building, the frame 311 can be released by disconnecting each support member 384 from the associated socket 383.
Referring now to
In this modification, a rack and pinion mechanism 490 is provided to assist when the room module 402 or service module 403 are inserted in and removed from the frame 411. As shown, each module 402,403 is provided on the underside with a longitudinal rack 491 that is located centrally between the sides of the module and extends from one end to the other end.
The rack 491 engages a pinion 492 located on the frame 411 at the entrance to the space 419 in which the module is received. The pinion 492 is driven by a motor 493 which can be operated remotely by any suitable means (not shown). In use, the module 402,403 is lifted to align and locate the module in the entrance to the space 419 in which the module 402,403 is to be inserted. The rack 491 is engaged with the pinion 492 and the pinion 492 is then driven to locate the module 402 in its final position in the space 419. Removal of the module 402,403 is the reverse of the above operation.
The motor 493 may be removable to allow the motor 493 to be used to insert/remove modules at different locations in the frame 411. In this way, a separate motor for each space is not required. Each space 419 may have its own pinion 492. Alternatively, the motor 493 and pinion 492 may be combined and moved together as a unit for location at a space 419 where a module is to be inserted or removed.
Opening, closing and locking of the doors 425 (cladding) for access to a space 419 when inserting/removing a module may be remotely controlled by any suitable means such as a building management system (BMS) which may also control the rack and pinion mechanism 490. The modules may still be located and supported by suitable guides on either side and/or above or below while being moved into and out of the frame 419 by the rack and pinion mechanism 490.
Referring now to
As shown the module 502,503 is provided with two laterally spaced brackets 530 at the front end that are aligned with two of laterally spaced brackets 531 located towards the rear end. Each pair of front and rear brackets 530,531 receives a lifting fork 532 of a crane or other suitable lifting device for raising and lowering the module 502,503. The rear brackets 531 are tapered in the direction of insertion of the forks 532 to assist in maintaining the module 502,503 level.
In this embodiment, the module 502,503 is provided on each side with front and rear castor wheels 533,534 that engage a channel section guide or track 535 supported on the frame 511. In use, the module is lifted with the forks 532 to align with the space 519 in the frame 511 and the forks 532 extended to insert partially the module 502,503 in the space 519. The module 502,503 is then moved fully into the space 519 by any suitable means such as the rack and pinion mechanism described previously.
The castor wheels 533,534 assist sliding movement of the module 502,503 into and out of the space 519 and, when the module 502,503 is fully inserted, the castor wheels 533,534 may be adjusted with shims (not shown) or other suitable means to adjust the level of the module 502,503 in the space 519. The castor wheels 533,534 may replace the guide means of previous embodiments or may be employed in combination with such guide means.
Referring now to
In this modification, a hydraulic ram 636 is provided to assist inserting/removing the module 602,603 from a space 619 in the building. The ram 636 has a piston 637 that co-operates with a bracket 638 on the underside of the module 602,603 to move the module 602,603 to or from it s final position in the space 619 during installation/removal of the module as described previously.
Referring now to
As will now be understood from the foregoing description of exemplary embodiments, the building according to the invention is advantageous as it simplifies construction of the building and allows the lay-out of the building to be adapted/altered according to user requirements.
The sliding mechanism aids insertion of modules into and removal of modules from the frame. Furthermore, modules can be replaced easily without damaging exterior weather proofing or roofing, or disrupting the services supplied to other modules.
In addition, tradesmen can access the modules from the outside of the building for removal and therefore, do not/only require minimal access to the “clean” area, helping to avoid any compromise of the integrity of the “clean” area by the tradesmen. In this way, modules can be removed and replaced with no or minimal downtime to the remainder of the building.
By providing service modules, the connections for supplying services can be constructed and tested remote from the building site and retested on site, speeding up and simplifying construction once at the building site.
In an alternative embodiment (not shown), the modules in the inner ring (dirty area) are removable modules, similar to the modules in the outer ring (clean area). A tradesmen entrance is provided to the central courtyard to allow the tradesmen to access the modules in the inner ring for removal. In this way, the inner ring can be adapted to changing user requirements. An inner ring of removal modules could be used as a “dirty” area as described or as a further “clean” area.
The building according to the invention is particularly suitable for use as research centres, hospitals and veterinary centres where it is desirable to have a building that can be adapted to changing requirements while maintaining a decontaminated environment.
However, it will be understood that a building according to the invention is not limited to such use and may be used for buildings for other uses in which it is not necessary to have “clean” and “dirty” areas. For example, the invention has application to buildings where the layout of the building may require alteration during the lifetime of the building to accommodate changes in the working environment. For example, buildings according to the invention could find use as offices, schools or the like. Furthermore it will be understood that the invention has application to buildings of all shapes and lay-out according to the intended application.
The modules can be installed in existing modular buildings comprising a load bearing steel frame and in which the modules of the building do not form a load bearing part of the structure. The modules can be used to replace or supplement existing modules.
According to another aspect, the invention provides a building system comprising a frame defining a plurality of apertures to receive pre-fabricated modules to form a building having a pre-determined lay-out, wherein the modules can be inserted in and removed from the apertures independently of other modules such that the lay-out of the building can be adapted to user requirements.
The modules may comprise modules in which people can live, work etc and modules in which services for the primary modules can be located.
Claims
1. A building comprising a plurality of prefabricated modules, wherein each module is removable from the building independently of the other modules and without compromising the integrity of the building.
2. A building according to claim 1 further comprising a weatherproof exterior surrounding the modules and each module is removable from the building without damaging the weatherproof exterior.
3. A building according to claim 1 further comprising a frame in which the modules are removably mounted.
4. A building according to claim 3 in which the frame is made of steel.
5. A building according to claim 3 in which the frame provides support for external cladding and roofing of the building.
6. A building according to claim 5 in which the external cladding is removable to allow access to the modules for removal and insertion of the modules.
7. A building according to claim 6 in which the removable cladding is a plurality of panels mounted on the outside of the frame and arranged to be detachable from the frame to allow access to modules for removal and re-attachable to the frame once the module has been removed/replaced.
8. A building according to claim 6 in which the removable cladding is a plurality of weather tight doors permanently mounted on the frame and movable from a closed position concealing the modules to an open position allowing access to modules for removal.
9. A building according to claim 8 in which the doors are pivotally mounted to the frame.
10. A building according to claim 3 in which means is provided to facilitate insertion and removal of the modules into and from the frame.
11. A building according to claim 10 in which the means is a mechanism, which allows the modules to be slid into and from the frame.
12. A building according to claim 11 in which the mechanism comprises pairs of horizontal skids on the frame and/or modules, each pair of skids arranged to allow a module to slide across the frame to guide and support the modules during insertion and removal.
13. A building according to claim 11 in which the mechanism comprises guides mounted on the frame that have formations that inter-engage with runners on the module to allow sliding movement of the modules relative to the frame during insertion and removal of the modules.
14. A building according to claim 13 in which the guides are mounted on sides of the frame and the runners on outer sidewalls of the modules.
15. A building according to claim 14 in which the modules are located in the frame both horizontally and vertically by inter-engagement of the runners with the guides.
16. A building according to claim 1 further comprising means for supplying services to the modules.
17. A building according to claim 16 wherein prefabricated service modules are provided housing the service supplying means.
18. A building according to claim 17 wherein the service modules are located in between removable modules.
19. A building according to claim 18 wherein the removable modules are detachably connected to the services such that the module can be disconnected from the services for removal from the building without damaging the service supply and disrupting the supply of services to other modules.
20. A building according to claim 19 wherein the removable modules are suitable for forming part of a decontaminated area of the building.
Type: Application
Filed: Dec 27, 2005
Publication Date: Jun 28, 2007
Inventor: Kevin Hourihan (Beyton)
Application Number: 11/319,141
International Classification: E04H 6/00 (20060101); E04H 1/00 (20060101);