GB2478373A

GB2478373A - A system for temporarily connecting support legs to shipping containers

Info

Publication number: GB2478373A
Application number: GB1021043A
Authority: GB
Inventors: Narinder Assi; Nico Lenkeit; George Petirides
Original assignee: KEY HOUSING Ltd
Current assignee: KEY HOUSING Ltd
Priority date: 2009-12-14
Filing date: 2010-12-13
Publication date: 2011-09-07
Anticipated expiration: 2030-12-13
Also published as: GB2476102A; GB2487650B; GB2478373B; GB201201036D0; GB0921744D0; GB2487650A; GB201021043D0

Abstract

Each module, preferably an ISO container, has half of a locking device 81 facing outwards from a structural element. The other half of the locking device 81 is preferably attached to an outer column member 86. The locking devices are preferably twist-lock or bayonet couplings. The column members preferably have shipping fittings 21 (figs 8a, 9d) in ISO positions to allow the module to be lifted and moved with the external columns attached. In use, the external columns provide a support frame which prevent damage to the module in transit, and are detachable after final positioning. A decorative panel can then be connected using the same locking system. The modules are preferably prefabricated with floor and ceiling, and connected together to form a living space with a shared roof. Also claimed are a box-shaped module, a ground fixing point, a recoverable external support, a sound insulation element and a gasket.

Description

MODULAR CONSTRUCTION SYSTEM

This invention in one aspect relates to a modular construction system.

Attempts to design transportable modular construction systems for permanent housing and buildings (by this is meant a building having a life expectancy of at least 60 years in which the major components are modular and assembled off site) have been unsuccessful because these buildings have had serious corrosion and/or condensation problems. As a result modular construction has largely been confined to short term temporary buildings where these issues are less of a problem. Furthermore the modules have often been difficult and expensive to transport, and when transported as shipping containers become damaged.

According to the present invention a modular building construction system comprising one or more modules in which one or more structural elements of the modules has one half of a locking device facing outwards from the structural member to receive the other half of the locking device attached to another item. For transport an outer column member is attachable to and detachable said structural element of a module when stacked and prevents damage to it during transport. Shipping fittings mounted on the external columns allow the module to be lifted and moved during transport by standard container lifting cranes.

I

The outer column can be removed when the module is located in its final position and other panels, decorative or otherwise fitted to the locking device, by fitting the panels with the other half member of the locking device. Ideally the locking device is a bayonet coupling.

Normally the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members linking the tops and bottoms of the vertical members.

A modular building construction system one or more of the four vertical members may comprise an inner column being a structural element of the module, and an outer column which is removable from the inner column by unlocking the locking device.

The modules may have floor joists installed to add strength and rigidity, and also to support any flooring finishing. The floor joists may be mounted transversely between the members forming the bottom perimeter. Similarly the modules may have ceiling joists which may be mounted transversely between the members forming the top perimeter. It is part of this invention that the modules can be used as shipping containers prior to their arrival on site and with this in mind preferably at least two dimensions of the frame comply with international standard dimensions for shipping containers.

Bracing members may be provided on the sides of the frame for rigidity during transit.

To add strength when the modules are constructed into buildings the modules may have additional intermediate vertical members within the sides of the frame. In this configuration intermediate fittings substantially identical to ISO container standard shipping fittings are provided top and bottom of intermediate members.

Modules can be locked together using a locking means to engage corner fittings and intermediate fittings. Particular features of the locking means which are useful in the current invention are set out

in the description below and the claims.

Slack between the locking means and the corner and intermediate fittings may be taken up by use of an additional fitting having upstanding shaped portions towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion between the wedge shaped portions to enable the fitting to be arranged around the longer sides of a rectangular aperture of a corner or intermediate fitting. These fittings are not tied to this invention, and can be applied to locking systems.

A particular feature of the invention is a new locking means adapted to engage shipping fittings on the modules so that modules can be firmly fixed to each other top and bottom and side by side. One embodiment of such a locking means is described below and in the claims.

A ground fixing point may also be provided to receive a locking means by which shipping fittings may be coupled to the ground fixing point by a locking means to firmly attach modules in respect of the ground.

In a further embodiment of the invention partitions within or between modules are isolated from floors or ceilings in a construction by flat resilient material with serrations on one side.

Although invented in connection with the modular construction system described herein the isolation strip is capable of application to other building systems to insulate the building against sound transmission. Thus in another aspect of the invention a sound insulation strip is provided comprising a flat resilient materials with serrations on one flat side, to be engaged between one element of a building (such as a partition) and another (such as a floor of ceiling).

Sound transmission can be reduced by providing that floor joists have a reduced cross section at one or more places along their length. The reduced cross section can be provided by perforations.

Similarly members linking the bottoms of the vertical members have a reduced cross section at one or more places along their length.

Gaskets may be provided to seal gaps between individual modules, the gasket comprise a deformable hollow portion between lateral blades to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.

These gaskets may be used separately to seal other gaps and are not uniquely applied to this construction system. Features of the gaskets are described below and identified in the claims.

The walls of the modules may be fitted with a vapour control membrane. The modules themselves may be made and sold separately otherwise than as part of the construction system.

In another aspect of the invention a building comprises one of the modules as previously described.

Other features of the invention are described below and in the claims.

The invention will be illustrated, by way of example, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a building constructed using a modular construction system according to the invention; Figures 2 and 3 illustrate standard and extended units respectively; Figure 4 shows a partially cut-away module for use with the invention; Figure 5 illustrates a corner lock fitting for use with the invention; Figure 6 shows a twist lock fitting; Figure 7 shows the mounting means for fixing ground floor modules to the ground; Figures 8A to 8C show the use of bearing corner pieces to support a stack of modules; Figures 9A to 9E show in more detail the locking devices; Figure 10 shows sound proofing and insulation systems for use with the invention; and Figure 11 shows gaskets to seal gaps between individual modules to exclude wind and rainwater.

The modular construction, shown, uses shipping containers as modules to make braced steel framed buildings. These are constructed using International Standards Organisation (ISO) freight container unit sizes. Bespoke non-standard size modules and infill panels are also used.

The modules can be arranged and connected together to form buildings of volumetric units fabricated industrially and fitted with finishes and equipment.

The containers can be fabricated anywhere and transported by sea and road to the destination country in the same manner as ISO freight containers.

In figure 1 the modules 1 are arranged and joined together with connections 2 to form buildings of a variety of shapes on foundations 3, with site fixed infill panels 4. The connection 2 is showing in more detail in figure 6; corner pieces are shown in figure 5. The modules may arrive with the exterior cladding fitted or will be clad on site with brickwork or some other cladding. The modules 1 can be used to transport additional panels 4 which can be inserted between the modules 1 as part of a hybrid volumetric and flat pack system. The units may be offset with respect to one another (labelled) 5, which allows scope for angled or curved architectural aesthetic features. Other components such as external claddings 6, parapets, pitched roofs 7, corridor floor 8 and wall panels can all be remotely manufactured at a factory and transported within the modules 1. Partitions 9 may be included within and between modules; these are described more fully with reference to figure 10.

The module 1 is a new type of container, what the inventor has called a Shipping Building Container (SBC), that has the ability to initially transport freight, to be handled like standard shipping containers and can later be assembled together in order to provide permanent building accommodation i.e. flats, houses, cluster housing, hotel bedrooms as part of the modular construction system.

The modules 1 have the following characteristics * They are able to carry heavy loads and support heavy loads when they are stacked in high columns. The modules can be located anywhere on a container vessel with other freight containers stacked up above or below and are also designed to satisfy structural requirements of a permanent building structure (wind, live and dead loads, seismic etc.).

* They resist harsh environments during transportation globally on ocean going vessels or transported on land. As part of the permanent Modular Construction System, the structural steel frame has a design life in excess of 60 years and a target life of the structural steel protection system of 75 years, thus providing permanent building solutions.

They are made to standard measurements and as such provide modular elements that can be combined into larger structures. Modular sizes include all standard ISO freight container unit sizes (including High Cube) as well as bespoke non standard sizes. In all cases the modules 1 are fitted with standard ISO Container corner shipping fittings, at the same locations as standard containers, which conform to standard shipping sizes, loadings and loading positions.

Figure 2 shows modules 1 of standard sizes. One module, meeting ISO standards, is shown and is 40 feet long. Another standard module is shown which is 20 feet long. In both cases the widths and heights are to ISO standards. The shipping fittings 21 are provided at the corner of these standard modules.

Figure 3 show examples of modules non standard sizes with the position of shipping fittings 21. In the case shown, the modules 1 are of standard length and height but wider than the norm In each case the shipping fittings locations 21 are separated from each other by the standard ISO lengths widths and heights, such that these non-standard size modules can still be joined to other modules.

The module 1 is shown in more detail in figure 4. It has a braced steel framed structure with vertical columns 41, with a perimeter top 42 comprising beams joined to the tops of vertical columns 41 and perimeter bottom 43 comprising beams joined to the bottom of vertical columns 41. The open frame formed between the vertical columns 41 and the perimeter top and bottom (42 and 43) is diagonally braced with bracing 44. Iso standard container corner fittings 21 are fitted at the same relative locations as on standard containers. Although these conform to standard shipping sizes, loadings and loading positions, they may but not necessarily be used to transmit loads in their permanent use in a building structure. In longer modules intermediate columns 46 with intermediate fittings 47 of similar design to corner shipping fittings 21 (hereinafter both intermediate fittings and corner shipping fittings 21 are called shipping fittings) are introduced and these are capable of transferring loads in their permanent use in a building structure. Floor joists preferably but not exclusively, pressed metal 48 that span across and are attached to the beams forming the perimeter bottom 43. These are lined with a membrane 49 that provides the waterproof lining and structural bracing. Internally are applied floor finishes 410 that can be varied depending on the final requirements.

Lightweight (for example steel, aluminium or timber) infill wall studwork 411 is covered internally with a decorative board 412 and externally with a sheathing board 413 that is faced with a waterproof lining 417.

Roof joists preferably but not exclusively pressed metal 414 span perimeter top 42. These are lined internally with a decorative board 415 and externally with a sheathing board 416 and further faced with waterproof lining 419.

A pitched roof (7 in Figure 1) may be attached to the beams forming the perimeter top 42. The pitched roof can be built in situ or more usually supplied as a complete pre-fabricated self supporting unit. The pitched roof (7 in figure 1) may be located above a single module 1, or may span a number of modules that are joined together as illustrated in figure 6 below.

The pitched roof can be attached to the tops of the vertical columns using the corner locking fittings as described below in figure 5, with the pitched roof having corner fittings similar to those described in figure 5 below.

Alternatively, a single preformed roof 420 may be attached above each modulel, or again span a number of modules. Such a roof can be formed as a single sheet from metal, or may be moulded from other suitable materials such a glass reinforced plastic.

Bracing is provided on all sides of the module through a mixture of metal cross bracing 44 or by the use of structural sheeting material such as plywood 49, 416. Metal cross bracing could be permanent or temporary and could be fitted anywhere along the plane of the wall fabric. The metal cross bracing 44 provides rigidity during transit but some or all can be removed when the module is finally positioned as part of a building.

It will be seen that in contrast to a normal shipping container the module does not have a shell skin structure and corrugated steel panels, but strength is given by and its replacement with a braced steel frame 41, 42, 43 and 44, with weatherproofed infill panels 413. Compared with conventional containers, this allows any moisture that is built up internally to escape through the wall.

Nevertheless a vapour control layer (such as a TyvekRTM vapour membrane), 418, is fitted behind the internal decorative lining 412 which controls the amount of vapour moving through the wall fabric.

This vapour control layer 418 can be sealed around windows and doors as well as penetrations such as sockets, ducts, pipes, flues within a factory environment that can achieve high standards of installation. This enables the modular system of this invention to achieve hugely improved air permeability through the fabric that is essential in low energy consumption buildings.

This arrangement as well as the improving the fabric of the new modular construction according to the invention creates a better internal environment. It also minimises the risk of damage to the contents of modules during transportation.

In other systems of this kind which use steel shells, the shell prevents the wall from breathing and any moisture within the building moving out may condense where it meets the meta' shell skin, with the potential long term risk of rust. With the risk of interstitial condensation leading to rust it would be difficult to demonstrate a target life of 75 years required for permanent construction. This invention enables that target to be met.

It should be noted that the expression "corner fitting" means a device of a kind normally fitted at the corners of ISO standard compliant shipping containers, it will be appreciated by reference to figure 3 that these devices are not necessarily located at the corners of modules for use in this invention. The ISO standard container shipping fittings 21 are shown in more detail in figure 5.

These corner fittings are fitted top and bottom of vertical columns 41 and comprise a hollow metal casting 22 having a plurality of rectangular apertures 23 aligned with the module such that the longer side 24 of aperture 23 is aligned top or bottom of the module with the longest side of the module.

Twist lock fittings 51 designed to engage with the corner fittings comprise a frame 512 in which a lever 511 is mounted perpendicularly on an axle, which itself is pivotally mounted in the frame 512. The axle is attached through the frame to lugs 514 to each side of the frame. The lugs have a generally rectangular cross section tapering from the end 515 closest to the frame to the other end 516, so that four sloping faces 517 are formed. Atop the frame 512 and below each lug an upstanding portion 518 is found. The dimensions of portion 518 are such that it will fit snugly within the rectangular apertures 23 of shipping fitting 21. The dimensions of lug 514 are such that it will pass through the rectangular portion 23 of casting 22, if offered to it, but when lever 511 and the axle is turned, the lugs will twist and catch on the periphery 25 of the aperture 23. The upstanding portions 518 will be drawn into a snug fit within aperture 23. In use the twist fitting is mounted into the corner fitting of one module and as a second module is offered to it, the sloping surfaces 517 will act as guides for the final positioning of the module adjacent to the first. Once in position the two modules can be joined simply by turning lever 511, causing lugs 514 to engage corner fittings of both modules.

Modules 1 are connected during transportation with the twist lock 51 that enable containers to be easily locked together and have an inherent slack in order to accommodate varying tolerances.

These twist locks 51 or variations of these see figures 6 and 7 are also used to structurally connect the modules in their permanent condition. These offer the benefit of speed in locking together.

In order to remove the inherent slack when the twist lock 51 engages shipping fitting 21, an additional new fitting 53 is used which is inserted into casting 22 prior to assembly of the modules 1 in their permanent condition. Fitting 53 is flexible for ease of inserting into the casting 22. It is generally composed of, but not limited to a composite of profiled structural rubber and steel. It is of wedge form 55 on one side in order to positively engage the lugs 514 of the twist lock 51 and casting 22 to remove inherent slack. A thinner portion 57 aligns with a shorter side of aperture 23. A flat outer part profile 56 isolates and protects the paint on the shipping fittings 21 frorri the steel twist 51.

Figure 6 shows how a number of modules are fitted together side by side and top to bottom. It will be seen that in such a configuration access to the locks is difficult. This is overcome by a twin lock 61 similar in principle to the twist lock 51 shown in figure 5. The twin lock 61 is used to enable four modules 1 to be locked together at fittings 47 on columns 46 (figure 4) and where access for locking is restricted.

This twin lock 61 is fitted with an upstanding wedge shaped guide 63 and is generally used with an extended locking arm 64 for the intermediate fittings. A short arm 65 can also be used if access is not a problem.

The twin lock 61 is designed to maintain a specified separation 66 between two adjacent modules and easily to guide the modules into position. It comprises two twist locking portions 62 each portion similar to the locks 51 of figure 5 linked by a connecting part 67.

Once the modules are installed the locking arm 64 (or 65) can be removed and reused.

Pairs of opposing lugs 68 are pivotally mounted within each portion 62 and operate in a similar way to lugs 514 in figure 5.

In use modules are lowered onto each other but are separated by the depth of twin lock 61, adjacent modules are separated by the wedges 63. The lugs 68 are pivotally mounted on axles operated by the locking arms 64 or 65, and engage through apertures 472 in the fittings 47. Once in place the locking arms are twisted to cause the lugs 68 to engage the periphery 471 of apertures 472. The overall shape and configuration of fittings 47 are similar to shipping fittings 21 described in figure 5.

Figure 7 shows how modules may be mounted on the ground. Here a base plate 71 has an upstanding cast ground fixing 72 with a locking device 73 for transferring load from the modules 1 to the foundations 74. The modules have cast steel shipping fittings 21 as shown in figure 2.

The twist lock 51 is shown in more detail in figure 5. It has a pair of opposed wedge shape rectangular cross section lugs 514. The maximum cross section of the lugs 514 is proportionally the same as but slightly smaller than apertures 76 in the tops of ground fixing 72 and aperture 23 in the bottom of shipping fitting 21. The lugs 514 are pivotally connected to a locking arm 511. The locking device 51 is initially located in its unlocked condition with one of the lugs 514 located in aperture 76.

As module 1 is lowered into position, the wedge shape of the upper lug 514 engages in aperture 23 and finally guides the shipping fitting 21 (and thus module 1) into place. The module 1 is locked into place by turning arm 511 50 that the upper lug 514 engages the periphery 25 of aperture 23.

Inserts as described in figure 5 can be located into the ground fixing 72 and shipping fitting 21 to ensure that no movement of the module can take place.

Similar arrangements can be made to join fittings 47 (figure 6) to the ground.

Figures 8A to 80 illustrate a locking device 81 used to temporarily or permanently fix two structural elements together in order to transfer load from one to the other.

Modules 1 are fitted with ISO container shipping fittings 21 at the same locations as standard containers conforming to standard shipping sizes, and are loaded as shown by 87 in figure 8A. These shipping fittings 21 always protrude beyond all other parts of a container.

Protrusion of the corner fittings imposes certain difficulties with some potential cladding solutions to the modular construction system of the present invention. It also limits the possibility of transporting modules, fully insulated and with the external cladding pre-fitted prior to transportation.

In order to avoid these problems support columns can be designed so that they can be removed prior to final assembly, as shown in Figure 8B. This development utilises two columns for each corner of the module 1. The inner column 85 will transfer vertical loads in the permanent condition and the outer support column 86 will transfer loads during transportation. The outer column is securely attached to the inner column using a new locking device 81.

The approach shown in Figure 8B is the one preferred where inner column 85 is the structural element to which the removable support column 86 can be fixed, however, the outer support column 86 may be fixed to its proposed interface located on any appropriate structural element. A possible alternative arrangement is shown in figure 8B. Here the removable support column 86 may me located via the locking devices 81 to cross members 88 and 89 top and bottom respectively of container 1.

It will be appreciated that inner column 85 may also form the vertical column 41 shown in Figure 4; likewise transverse members 88 and 89 may be part of the perimeter top 42 and bottom 43 shown in Figure 4.

This locking device 81, shown in more detail in figure 9, has a bayonet type fitting and is made up of a number of parts. The cast steel fitting plate 91 securely fitted to the inner column 85 at the factory incorporates the fixed part of the bayonet fitting 93. The outer column fitting 86 acts as a sleeve ready to accept the rotating bayonet fitting 95 which securely locks the outer and inner columns together. A tool fitting 96 is inserted and is used to rotate fitting 95 and securely engage into fitting 93. The shipping fittings 21 are fitted to the outer column 85.

These fittings are made and assembled at the factory and can achieve the high precision and quality control necessary for such a crucial structural connection.

Prior to final assembly the outer columns 86 and shipping fittings 21 can be unlocked, removed and returned to the factory to be used for the next assembly.

The modules are then assembled without the protruding corner columns. The inner columns 86 are then equivalent to vertical members 41 shown in figure 4, and modules are locked together using fittings 47 (figures 4 and 6).

This novel locking device can also be used to structurally connect two independent structures together. One such other use is shown in figure 1 to connect bespoke site fixed infill 4 to the corner columns of the module 1.

The scope of such a device is not limited to the connection of modules and can be used to connect other structural modules and components. One such use would be to connect the removable corner columns to an object that can be transported without the need of being within a container. The corner columns can then be directly fitted to the object and removed once it has reached its final destination.

Figure 10 shows a new sound proofing fitting 101 developed to be used in conjunction with a partition system 102 within a modular construction system according to the invention to allow flexible use of space within and between housing units. This allows room space within homes made from the modular construction system, and homes to be subdivided (see partitions 9 in figure 1) within a module.

The partition system 102 reduces airborne sound transmission as well as to improve the isolation from adjacent floor 103 and wall structures. The fitting 101 is a linear strip extrusion of a resilient material comprising a flat top 104 and a serrated underside 105.

Bottom tracks 106 of an internal partition wall are installed flush with the flat top of the strip fitting. To improve airborne sound performance, the bottom edge of any planking 107 (such as plasterboard) can be rested on the strip fitting in order to eliminate any cracks. Uneven floor decks and tolerances cause gaps between bottom tracks and floor, allowing airborne sound transmission. The serrated underside 105 of fitting 101 adapts to uneven surfaces and forms several linear sound barriers. It also decouples the partition system from any impact sound introduced through the floor.

The fitting 101 can be used in conjunction with existing sound proof lightweight steel stud (or timber stud) partitioning wall systems, Modifications made to the chassis structure (beams forming the bottom perimeter 43 and joists 48 in figure 4) in order to suppress structural flanking transmission through it.

A series of perforations 109 made to steel floor joists 48 will reduce the joist cross-section at strategic locations. Flanking sound transmission along the floor joists is consequently reduced.

In figure 11 gaskets that can be used externally to fill the gap between modules and deal with relevant demands of maintaining the inherent qualities of the exterior fabric of the permanent building. This push fit cover system deals with weathering demands like wind and rainwater.

The gaskets have a hollow interior 110 which will deform when inserted between modules and are made of a resilient material such as rubber, silicone or similar to allow for tight-fit due to compression. Rows of flexible blades 111 to either side of the gasket adapt to any tolerances and unevenness between modules.

Two types of linear gaskets are used: * A first type 112 to seal horizontal gaps and comprising of a shaped top edge 114 to direct any water away from the gap to be sealed; a overlapping down stand edge 115 protects from water ingress * A second type 113 to seal vertical gaps and comprising of an overlapping edge 125 to either side to protect from water ingress The gasket system is completed with corner and intermediate sections, (internal corner pieces 116, external corner pieces 117, "T"-shaped pieces 118, "X"-shaped pieces 119, "L"-shaped pieces 120) all of which have extended ends 121 to overlap and seal straight gaskets 112 and 113.

Claims

CLAIMS1. A modular building construction system comprising one or more modules characterised in that one or more structural elements of the modules has one half of a locking device (81) facing outwards from the structural member to receive the other half of the locking device attached to another item.
2. A modular building construction system according to claim 1 characterised in that said other item is an outer column member (86) is attachable to and detachable said structural element of a module.
3. A modular building construction system according claim 1 or 2 characterised in that shipping fittings (21) allow the modules to be lifted and moved are fitted to the outer column (86).
4. A modular construction system according to claim 2 or 3 characterised in that the outer column (86) is removable when the module is located in its final position.
5. A modular building construction system according to claim 1 characterised in that said other item is a decorative or other panel.
6. A modular building construction system according to any preceding claim characterised that locking device (81) is a bayonet coupling.
7. A modular building construction system according to any preceding claim characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members.
8. A modular building construction system according to claim 7 characterised in one or more of the four vertical members comprises an inner column (85), the inner column (85) being a structural element of the module, and the outer column (86) is detachable from the inner column (85) by unlocking the locking device (81).
9. A modular construction system according to any preceding claim characterised in that the module is provided with floor joists (48).
10. A modular construction system according to claim 9 characterised in that the floor joists (48) are mounted transversely between the bottom perimeter members (43).
11. A modular construction system according to any preceding claim provided with ceiling joists (414).
12. A modular construction system according to claim 11 in which the ceiling joists (414) are mounted transversely between top perimeter members (42).
13. A modular construction system according to claim 12 having a roof spanning between the top perimeter members (42).
14. A modular construction system according to any preceding claim characterised in having a self supporting roof unit (7, 420).
15. A modular construction system according to claim 14 characterised in that the roof unit is prefabricated.
16. A modular construction system according to claim 14 or 15 characterised in that the roof unit spans a plurality of modules.
17. A modular construction system according to any one of claims 14 to 16 characterised in that the roof unit forms a pitched roof.
18. A modular construction system according to any one of claims 14 to 16 characterised in that roof unit is formed from a single sheet of metal or moulded material.
19. A modular construction system according to any preceding characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.
20. A modular construction system according to any preceding claim characterised in that one or more modules has one or more additional intermediate vertical members (46) between vertical corner members.
21. A modular construction system according to claim 20 characterised in that the intermediate members (46) have shipping fittings (47) mounted top and bottom thereof.
22. A modular construction system according to any preceding claim having locking means (51) to engage shipping fittings.
23. A modular construction system according to claim 22 characterised in that the locking means (51) comprises opposing lugs (514) pivotally mounted on a frame (513), such that in one position a lug is free to enter and leave an aperture (23, 472) of a shipping fitting (21,47), and in another position the lug engages said fixing.
24. A modular construction according to claim 22 characterised in that the frame (513) has at least one upstanding portion to engage as a snug fit within the said apertures when the locking means is in its locked condition.
25. A modular construction system according to claims 23 or 24 characterised in that said the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fitting (21, 47), the portion of the lug (516) furthest from the frame being of smaller cross section that the portion nearest the frame such that sloping faces (517) are formed on the lug to help final location of a module (1) when a building is being constructed.
26. A modular construction system according to any one of claims 22 to 25 in having a deformable wedge shaped portion within one of more of the shipping fitting (21, 47) to be engaged between a lug (514) and the periphery (25, 471) of said apertures in the shipping fittings.
27. A modular construction system according to any preceding claim characterised in that it has one or more further fixings comprising an elongated flexible member having upstanding wedge shaped portions (55) towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion (57) between the wedge shaped portions to enable the further fixings to be arranged around the longer sides (24) of a rectangular aperture of a shipping fitting (21, 47).
28. A modular construction system according to claim 21 characterised in that it has a twin locking means (61) adapted simultaneously to engage four corner and/or intermediate fittings.
29. A modular construction system according to claim 26 characterised in that the twin locking means (61) comprises a mounting plate 67 having, towards each end,frames in which are pivotally mounted pairs of opposed lugs and to engage with the shipping fitting (21,47) to fix a plurality of modules (1) in juxtaposition.
30. A modular construction system according to claim 27 characterised in that the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fittings (21, 47) the portion of the lug furthest from the frame is of srrialler cross section that the portion nearest the frame whereby sloping faces thus created on the lug to help final location of modules (1) when a building is being constructed.
31. A modular construction system according to claim 29 or 30 characterised in having wedges (63) on the mounting plate (67) to guide the location of modules (1).
32. A modular construction system according to any one of claims 29 to 31 characterised in that it has an elongate handle (64) to urge locking means (61) into its locked position.
33. A construction system according to claim 32 characterised in that the handle is detachable.
34. A modular construction system according to any preceding claim characterised in including a ground fixing point (72) and a locking device (51) coupling a shipping fitting (21, 47) to the ground fixing point.
35. A modular construction system according to any preceding claim characterised in that partitions within or between modules are isolated from floors or ceilings in a construction by flat resilient material (101) with serrations (105) on one side.
36. A modular construction system according to claim 9 characterised in that one or more floor joists (48) have reduced cross section at one or more places along their length.
37. A modular construction system according any preceding claim in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.
38. A modular construction system according to claim 36 or 37 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.
39. A modular construction system according to any preceding claim characterised in that a resilient gasket (112, 113) seals gaps between individual modules (1), the gasket comprising a deformable hollow portion (110) between lateral blades (111) to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.
40. A modular construction system according to claim 39 characterised in that a gasket (112) has a bevelled portion (114) to direct water away from the surface of a module.
41. A modular construction system according to any preceding claim characterised in that it has a vapour control membrane (418) fitted to the walls of the modules (1).
42. A locking means for a modular construction system characterised in that it comprises opposing lugs (514) pivotally mounted on a frame (513), such that in one position a lug is free to enter and leave an aperture (23, 472) of a corner or intermediate shipping fitting (21, 47) on a module of the construction system and in another position the lug engages said shipping fitting.
43. A locking means according to claim 42 characterised in that the frame (513) has at least one upstanding portion to engage as a snug fit within the said apertures when the locking means is in its locked condition.
44. A locking means according to claims 42 or 43 characterised in that said the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fitting (21, 47), the portion of the lug (516) furthest from the frame being of smaller cross section that the portion nearest the frame such that sloping faces (517) are formed on the lug to help final location of a module (1) when a building is being constructed.
45. A locking means according to any one of claims 42 to 44 in having a deformable wedge shaped portion within one of more of the shipping fittings (21, 47) to be engaged between a lug (514) and the periphery (25, 471) of said apertures in the fixings.
46. A locking means according to any one of claims 42 to 45 further comprising an elongated flexible member having upstanding wedge shaped portions (55) towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion (57) between the wedge shaped portions to enable the further fixings to be arranged around the longer sides (24) of a rectangular aperture of a shipping fitting (21, 47).
47. A locking means according to any one of claims 42 to 46 characterised in that it is a twin locking means (61) adapted simultaneously to engage four shipping fittings.
48. A locking means according to claim 47 characterised in that the twin locking means (61) comprises a mounting plate (67) having, towards each end, frames in which are pivotally mounted pairs of opposed lugs and to engage with the shipping fittings (21,47) to fix a plurality of modules (1) in juxtaposition.
49. A locking means according to claim 48 characterised in that the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fittings (21, 47), the portion of the lug furthest from the frame is of smaller cross section that the portion nearest the frame whereby sloping faces thus created on the lug to help final location of modules (1) when a building is being constructed.
50. A locking means according to claim 48 or 49 characterised in having wedges (63) on the mounting plate (67) to guide the location of modules (1).
51. A locking means according to any one of claims 48 to 50 characterised in that it has an elongate handle (64) to urge the locking means (61) into its locked position.
52. A locking means according to claim 51 characterised in that the handle is detachable.
53. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that it has having floor joists.
54. A module according to claim 53 characterised in that the floor joists (48) are mounted transversely between the bottom perimeter members (43).
55. A module according to claim 54 characterised in that one or more floor joists (48) have reduced cross section at one or more places along their length.
56. A module according any one of claims 53 to 55 in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.
57. A module according to claim 55 or 56 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.
58. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.
59. A modular construction system characterised in that partitions within or between adjoining modules are isolated from floors or ceilings of individual modules by flat resilient material (101) with serrations (105) on one side.
60. A module for use in a modular construction system characterised in that it has a vapour control membrane (418) fitted to the walls of the modules (1).
61. A module for use in a modular construction system characterised in that it is a self supporting roof (7, 420).
62. A module according to claim 61 characterised in that the module is prefabricated.
63. A module according to claim 61 or 62 characterised in that the roof module will span a plurality of other modules when assembled in the final construction.
64. A module according to any one of claims 61 to 63 characterised in that the module comprises a pitched roof.
65. A module according to any one of claims 61 to 64 characterised in that roof unit is formed from a single sheet of metal or moulded material.
66. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that it has having floor joists: in that floor joists (48) are mounted transversely between the bottom perimeter members (43); in that one or more floor joists (48) have reduced cross section at one or more places along their length and in that a vapour control membrane (418) is fitted to the walls of the modules (1).
67. A module according claim 66 in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.
68. A module according to claim 66 or 67 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.
69. A module for a modular building construction system according to any one of claims 66 to 68 characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.
70. A modular construction system comprising a plurality of modules according to any one of claims 66 to 68 characterised in that partitions within or between adjoining modules are isolated from floors or ceilings of individual modules by flat resilient material (101) with serrations (105) on one side.
71. A gasket for use in a modular construction system characterised in that comprises a deformable hollow portion (110) between lateral blades (111) to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.
72. A gasket according to claim 71 characterised in that the gasket (112) has a bevelled portion (114) to direct water away from the surface of a module.
73. A ground fixing point for a construction module characterised in including a shipping fitting (72) to receive a locking device (51) to coupling a shipping fitting (21, 47) in the module to the ground fixing point.
74. A modular construction system substantially as hereinbefore described with reference to the accompanying drawings.
75. A locking means substantially as hereinbefore described with reference to the accompanying drawings.
76. A module for use in a modular construction system substantially as hereinbefore described with reference to the accompanying drawings.
77. A gasket for use in a modular construction system substantially as hereinbefore described with reference to the accompanying drawings.
78. A ground fixing point for a construction module substantially as hereinbefore described with reference to the accompanying drawings.Amendments to the claims have been filed as followsCLAIMS1. A modular building construction system comprising one or more modules of substantially rectangular box-like container form characterised in that one or more structural elements of the modules has one half of a locking device (81) facing outwards from the structural member to receive the other half of the locking device attached to another item.2. A modular building construction system according to claim 1 characterised in that said other item is an outer column member (86) is attachable to and detachable said structural element of a module.3. A modular building construction system according claim 1 or 2 characterised in that shipping fittings (21) allow the modules to be lifted and moved are fitted to the outer column (86).4. A modular construction system according to claim 2 or 3 L() Q1S characterised in that the outer column (86) is removable when the module is located in its final position.5. A modular building construction system according to claim 1 characterised in that said other item is a decorative or other panel.6. A modular building construction system according to any preceding claim characterised that locking device (81) is a bayonet coupling.7. A modular building construction system according to any preceding claim characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members.8. A modular building construction system according to claim 7 characterised in one or more of the four vertical members comprises an inner column (85), the inner column (85) being a structural element of the module, and the outer column (86) is detachable from the inner column (85) by unlocking the locking device (81).9. A modular construction system according to any preceding claim characterised in that the module is provided with floor joists (48).10. A modular construction system according to claim 9 characterised in that the floor joists (48) are mounted transversely between the bottom perimeter members (43).11. A modular construction system according to any preceding claim Q provided with ceiling joists (414).12. A modular construction system according to claim 11 in which the ceiling joists (414) are mounted transversely between top perimeter members (42).13. A modular construction system according to claim 12 having a roof spanning between the top perimeter members (42).14. A modular construction system according to any preceding claim characterised in having a self supporting roof unit (7, 420).15. A modular construction system according to claim 14 characterised in that the roof unit is prefabricated.16. A modular construction system according to claim 14 or 15 characterised in that the roof unit spans a plurality of modules.17. A modular construction system according to any one of claims 14 to 16 characterised in that the roof unit forms a pitched roof.18. A modular construction system according to any one of claims 14 to 16 characterised in that roof unit is formed from a single sheet of metal or moulded material.19. A modular construction system according to any preceding characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.20. A modular construction system according to any preceding claim characterised in that one or more modules has one or more additional intermediate vertical members (46) between vertical Q corner members.21. A modular construction system according to claim 20 characterised in that the intermediate members (46) have shipping fittings (47) mounted top and bottom thereof.22. A modular construction system according to any preceding claim having locking means (51) to engage shipping fittings.23. A modular construction system according to claim 22 characterised in that the locking means (51) comprises opposing lugs (514) pivotally mounted on a frame (513), such that in one position a lug is free to enter and leave an aperture (23, 472) of a shipping fitting (21,47), and in another position the lug engages said fixing.24. A modular construction according to claim 22 characterised in that the frame (513) has at least one upstanding portion to engage as a snug fit within the said apertures when the locking means is in its locked condition.25. A modular construction system according to claims 23 or 24 characterised in that said the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fitting (21, 47), the portion of the lug (516) furthest from the frame being of smaller cross section that the portion nearest the frame such that sloping faces (517) are formed on the lug to help final location of a module (1) when a building is being constructed.26. A modular construction system according to any one of claims 22 to in having a deformable wedge shaped portion within one of more Q of the shipping fitting (21, 47) to be engaged between a lug (514) and the periphery (25, 471) of said apertures in the shipping fittings.27. A modular construction system according to any preceding claim characterised in that it has one or more further fixings comprising an elongated flexible member having upstanding wedge shaped portions (55) towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion (57) between the wedge shaped portions to enable the further fixings to be arranged around the longer sides (24) of a rectangular aperture of a shipping fitting (21, 47).28. A modular construction system according to claim 21 characterised in that it has a twin locking means (61) adapted simultaneously to engage four corner and/or intermediate fittings.29. A modular construction system according to claim 26 characterised in that the twin locking means (61) comprises a mounting plate 67 having, towards each end,frames in which are pivotally mounted pairs of opposed lugs and to engage with the shipping fitting (21,47) to fix a plurality of modules (1) in juxtaposition.30. A modular construction system according to claim 27 characterised in that the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fittings (21, 47) the portion of the lug furthest from the frame is of smaller cross section that the portion nearest the frame whereby Q sloping faces thus created on the lug to help final location of modules (1)when a building is being constructed.31. A modular construction system according to claim 29 or 30 characterised in having wedges (63) on the mounting plate (67) to guide the location of modules (1).32. A modular construction system according to any one of claims 29 to 31 characterised in that it has an elongate handle (64) to urge locking means (61) into its locked position.33. A construction system according to claim 32 characterised in that the handle is detachable.34. A modular construction system according to any preceding claim characterised in including a ground fixing point (72) and a locking device (51) coupling a shipping fitting (21, 47) to the ground fixing point.35. A modular construction system according to any preceding claim characterised in that partitions within or between modules are isolated from floors or ceilings in a construction by flat resilient material (101) with serrations (105) on one side.36. A modular construction system according to claim 9 characterised in that one or more floor joists (48) have reduced cross section at one or more places along their length.37. A modular construction system according any preceding claim in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.38. A modular construction system according to claim 36 or 37 Q characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.39. A modular construction system according to any preceding claim characterised in that a resilient gasket (112, 113) seals gaps between individual modules (1), the gasket comprising a deformable hollow portion (110) between lateral blades (111) to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.40. A modular construction system according to claim 39 characterised in that a gasket (112) has a bevelled portion (114) to direct water away from the surface of a module.41. A modular construction system according to any preceding claim characterised in that it has a vapour control membrane (418) fitted to the walls of the modules (1).42. A locking means for a modular construction system characterised in that it comprises opposing lugs (514) pivotally mounted on a frame (513), such that in one position a lug is free to enter and leave an aperture (23, 472) of a corner or intermediate shipping fitting (21, 47) on a module of the construction system and in another position the lug engages said shipping fitting.43. A locking means according to claim 42 characterised in that the frame (513) has at least one upstanding portion to engage as a snug fit within the said apertures when the locking means is in its locked condition.Q 44. A locking means according to claims 42 or 43 characterised in that said the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fitting (21, 47), the portion of the lug (516) furthest from the frame being of smaller cross section that the portion nearest the frame such that sloping faces (517) are formed on the lug to help final location of a module (1) when a building is being constructed.45. A locking means according to any one of claims 42 to 44 in having a deformable wedge shaped portion within one of more of the shipping fittings (21, 47) to be engaged between a lug (514) and the periphery (25, 471) of said apertures in the fixings.46. A locking means according to any one of claims 42 to 45 further comprising an elongated flexible member having upstanding wedge shaped portions (55) towards either end, the wedge shaped portions increasing in depth towards each end, and a thinner portion (57) between the wedge shaped portions to enable the further fixings to be arranged around the longer sides (24) of a rectangular aperture of a shipping fitting (21, 47).47. A locking means according to any one of claims 42 to 46 characterised in that it is a twin locking means (61) adapted simultaneously to engage four shipping fittings.48. A locking means according to claim 47 characterised in that the twin locking means (61) comprises a mounting plate (67) having, towards each end, frames in which are pivotally mounted pairs of opposed Q lugs and to engage with the shipping fittings (21,47) to fix a plurality of modules (1) in juxtaposition.49. A locking means according to claim 48 characterised in that the lugs have a generally rectangular cross section in proportion to the shape of the apertures (23, 472) in the shipping fittings (21, 47), the portion of the lug furthest from the frame is of smaller cross section that the portion nearest the frame whereby sloping faces thus created on the lug to help final location of modules (1) when a building is being constructed.50. A locking means according to claim 48 or 49 characterised in having wedges (63) on the mounting plate (67) to guide the location of modules (1).51. A locking means according to any one of claims 48 to 50 characterised in that it has an elongate handle (64) to urge the locking means (61) into its locked position.52. A locking means according to claim 51 characterised in that the handle is detachable.53. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that it has having floor joists.54. A module according to claim 53 characterised in that the floor joists (48) are mounted transversely between the bottom perimeter Q members (43).55. A module according to claim 54 characterised in that one or more floor joists (48) have reduced cross section at one or more places along their length.56. A module according any one of claims 53 to 55 in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.57. A module according to claim 55 or 56 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.58. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.59. A modular construction system characterised in that partitions within or between adjoining modules are isolated from floors or ceilings of individual modules by flat resilient material (101) with serrations (105) on one side.60. A module for use in a modular construction system characterised in that it has a vapour control membrane (418) fitted to the walls of the Q modules (1).61. A module for use in a modular construction system characterised in that it is a self supporting roof (7, 420).62. A module according to claim 61 characterised in that the module is prefabricated.63. A module according to claim 61 or 62 characterised in that the roof module will span a plurality of other modules when assembled in the final construction.64. A module according to any one of claims 61 to 63 characterised in that the module comprises a pitched roof.65. A module according to any one of claims 61 to 64 characterised in that roof unit is formed from a single sheet of metal or rrioulded material.66. A module for a modular building construction system characterised in that the one or more modules are substantially box shaped in which each module comprises a frame having a least four vertical members located at each end of the module, and top and bottom perimeter members (42, 43) linking the tops and bottoms of the vertical members characterised in that it has having floor joists: in that floor joists (48) are mounted transversely between the bottom perimeter members (43); in that one or more floor joists (48) have reduced cross section at one or more places along their length and in that a vapour control membrane (418) is fitted to the walls of the Q modules (1).67. A module according claim 66 in which the bottom perimeter members (43) have reduced cross section at one or more places along their length.68. A module according to claim 66 or 67 characterised in that said reduced cross section is formed by perforations (109) in the joists or bottom perimeter members.69. A module for a modular building construction system according to any one of claims 66 to 68 characterised in that the module has diagonal bracing members (44) in rectangles formed between vertical members and perimeter members, said bracing members being removable when the module is located in its final position.70. A modular construction system comprising a plurality of modules according to any one of claims 66 to 68 characterised in that partitions within or between adjoining modules are isolated from floors or ceilings of individual modules by flat resilient material (101) with serrations (105) on one side.71. A gasket for use in a modular construction system characterised in that comprises a deformable hollow portion (110) between lateral blades (111) to engage between adjacent modules, and a flat portion to seal the flat faces of adjacent modules against water ingress.72. A gasket according to claim 71 characterised in that the gasket (112) has a bevelled portion (114) to direct water away from the surface of a module.73. A ground fixing point for a construction module characterised in Q including a shipping fitting (72) to receive a locking device (51) to coupling a shipping fitting (21, 47) in the module to the ground fixing point.74. A modular construction system substantially as hereinbefore described with reference to the accompanying drawings.75. A locking means substantially as hereinbefore described with reference to the accompanying drawings.76. A module for use in a modular construction system substantially as hereinbefore described with reference to the accompanying drawings.77. A gasket for use in a modular construction system substantially as hereinbefore described with reference to the accompanying drawings.78. A ground fixing point for a construction module substantially as hereinbefore described with reference to the accompanying drawings. Q2O L()