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(11) | EP 1 609 921 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Improvements in or relating to buildings |
| (57) A modular building system for constructing a building comprises a frame 11 for detachably
mounting modules 2 providing rooms and modules 3 providing services to the rooms.
The service modules 3 are located between room modules 2 and the modules 2,3 can be
inserted in and removed from the frame 11 without compromising the integrity of the
building. |
[0001] This invention concerns improvements in or relating to buildings formed from prefabricated modules and to a building system for constructing buildings employing such pre-fabricated modules.
[0002] It 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.
[0003] 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.
[0004] 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.
[0005] In this way, the prefabricated modules can be removed and replaced, allowing the building to be adapted to changing user requirements.
[0006] The building may comprise a weatherproof exterior surrounding the modules and each module is removable from the building without damaging the weatherproof exterior.
[0007] 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.
[0008] 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.
[0009] 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 reattachable to the frame once the module has been removed/replaced.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] Embodiments of the invention will now be described, by example only, with reference to the drawings, in which:
Figure 1 shows a plan view of a modular building according to a first embodiment of the invention;
Figure 2 shows a section of the modular building of Figure 1 in the direction of arrow A;
Figures 2a, and 2b are enlarged views showing details of two alternative sliding mechanisms on the underside of the modules shown in Figure 2;
Figure 2c is an enlarged view showing details of the sliding mechanism on the sidewall of the modules shown in Figure 2;
Figure 3 shows a section of the modular building of Figure 1 perpendicular to that shown in Figure 2;
Figure 4 shows a section of a modular building according to a second embodiment of the invention;
Figure 4a is a enlarged view showing a detail of the closer member for adjacent modules shown in Figure 4;
Figure 5 shows a section of a modular building according to a third embodiment of the invention;
Figure 5a is a enlarged view showing a detail of the closer member for adjacent modules shown in Figure 5; and
Figure 6 shows a detail of a system for detachably installing the frame of the modular building according to the invention.
[0026] Referring first to Figure 1, a first embodiment of a modular building 1 according to the present invention is shown comprising a plurality of modules (pods) 2, 3 and 4 that are assembled together to form the building 1.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] With particular reference to Figures 2 and 3, the "clean" area of the building 1 will now be described in more detail.
[0032] 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. Figure 2 shows part of the grid forming the outer ring of modules in Figure 1.
[0033] 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 Figure 2, two room modules 2 are shown, mounted one above the other, to provide different storeys of the building 1. It will be understood that the building may comprise any number of storeys.
[0034] 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.
[0035] 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 (Figure 2a) arranged to slide along horizontal beams/panels 13 or rollers 15b (Figure 2b) arranged to run along horizontal guides. The units 15,16 aid transfer of the weight of the modules to the frame 11.
[0036] 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 (Figure 2c). The runners 20 slide along and the guides 21 by means (not shown) such as bearings, wheels, hydraulics, pneumatics, an air cushion, or mechanical or electrical push/pulling equipment to aid movement of the modules 2 into and out of frame 11. The units 17,18 aid location of the modules 2 both horizontally and vertically in frame 11 by the engagement of ridges 22 on the guides 21 in channels 23 of the runners 20.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] Referring now to Figure 4, there is shown a second embodiment of a modular building according present invention. Parts corresponding to the first embodiment are indicated by like reference numerals in the series 100 and will not be described in detail as their function and operation will be apparent from the description of the first embodiment.
[0049] 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.
[0050] The gap in the floor, wall, and ceiling between the modules 102a,b,c is filled by inserting a closer member 150 (Figure 4a) having a faceplate 150a in a finish to suit the position of the closer member 150.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] Referring now to Figure 5, there is shown a third embodiment of a modular building according present invention. Parts corresponding to the first and second embodiments are indicated by like reference numerals in the series 200 and will not be described in detail as their function and operation will be apparent from the description thereof.
[0056] In this third embodiment, the modules 202 are shown either side of a corridor 260 with service modules 203 above. The floor, walls and ceiling of the corridor 260 are sealed relative to the adjacent modules 202.203 where required by means of closer members 250 (Figure 5b) inserted into any gaps. The closer members 250 may also seal around doorways where doors are provided in the corridor 260.
[0057] Referring now to Figure 6, there is shown a system for installing the modular building of the present invention that enables parts of the system to be re-used. Parts corresponding to the first, second and third embodiments are indicated by like reference numerals in the series 300 and will not be described in detail as their function and operation will be apparent from the description thereof.
[0058] 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. 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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.
1. A building comprising a plurality of prefabricated modules (2,3;102,103;202,203) wherein
each module (2,3;102,103;202,203) is removable from the building independently of
the other modules (2,3;102,103;202,203) and without compromising the integrity of
the building.
2. A building according to claim 1 further comprising a weatherproof exterior surrounding
the modules (2,3;102,103;202,203) and each module (2,3;102,103;202,203) is removable
from the building without damaging the weatherproof exterior.
3. A building according to claim 1 or claim 2 further comprising a frame (11;111;211;311)
in which the modules are removably mounted.
4. A building according to claim 3 in which the frame (11;111;211;311) is detachably
attachable to a foundation structure and preferably provides support for external
cladding and roofing of the building forming the weatherproof exterior.
5. A building according to claim 4 in which the cladding (25) comprises a plurality of
panels mounted on the outside of the frame (11) and arranged to be detachable from
the frame (11) to allow access to modules for removal and re-attachable to the frame
once the module has been removed/replaced.
6. A building according to any one of claims 3 to 5 in which means (17,18;20,21) is provided
on the underside and/or each side of the modules (2,3;102,103;202,203) for sliding
the modules (2,3;102,103;202,203) into and out of the frame (11;111;211;311)
7. A building according to any one of the preceding claims wherein the modules (2,3;102,103;202,203)
includes room modules (2;102;202) and service modules (3;103;203) for supplying services
to the room modules (2;102;202).
8. A building according to claim 7 wherein adjacent sides of at least two adjoining modules
(102a,b,c) are open to connect the modules and means (150) is provided to close the
gap between the modules (102a,b,c).
9. A method of constructing a building comprising prefabricating a plurality of modules
(2,3;102,103;202,203), and assembling the modules (2,3;102,103;202,203) together to
form a building, wherein each module (2,3;102,103;202,203) is assembled to be removable
from the building independently from the other modules (2,3;102,103;202,203) and without
compromising the integrity of the building.
10. A method according to claim 9 wherein at least one module (2;102;202) is a room module,
and at least one module (3;103;203) is a service module having a predetermined arrangement
of connections for supplying services to the room module (2;102;202) when assembled
in a building and assembling the modules (2,3;102,103;202,203) together to form a
building with services supplied to the room modules (2;102;202) via the connections
in the service modules (3;103;203).