HK1161750A - Unitised building system - Google Patents

Abstract

The invention provides a method of building a building having a plurality of levels using. The building includes a plurality of building unit assemblies (2) wherein each building unit assembly is structurally self supporting and has at least one sidewall (4), a floor (8) and a roof (10), the method including the steps of: lifting the building unit assemblies (2) into position in the building so that each level of the building includes a predetermined number of units (2); connecting adjacent units (2) to one another in each level; and connecting units (2) in one level to corresponding units in at least one adjacent level that is vertically above or below the one level. In one form the building unit assembly (2) includes a building unit including two sidewalls (4) and (6) floor (8) and roof (10) with structural frame segments (16, 18, 20, 22) attached thereto.

Description

Unit type building system

Technical Field

The present invention relates to a building system. The invention will be described in connection with the construction of high-rise buildings, however the solution of the invention and its application outside this field and the invention should not be regarded as being limited to this exemplary field of use.

Background

There have been various proposals for using prefabricated building methodologies to inexpensively and quickly construct buildings. Examples of prefabricated modular systems include those disclosed in the following prior art documents: US 6,625,937; US 5,706,614; US 4,120,133; US 6,826,879; US 4,045,937; US 5,402,608; US 4,807,401; US 4,545,159 and WO 2005/038155.

However, in general, the prefabricated systems that have been proposed are only suitable for single-storey or low-storey buildings and are generally modular in approach so that there is an inherent inflexibility that limits their application.

It is an object of the present invention to provide a non-modular, flexible building system that can be used to construct high-rise buildings. A high-rise building is considered to be a building having four or more stories on the ground floor. However, it is clear that similar techniques can be applied to buildings of lower height without departing from the invention. It is an object of another aspect of the present invention to provide an improved technique for interconnecting units used in the construction of a building.

Disclosure of Invention

In one aspect of the present invention there is provided a method of constructing a building having a plurality of levels using a plurality of building unit assemblies, wherein each building unit assembly is structurally self-supporting and has at least one side wall, a floor and a roof, the method comprising the steps of: lifting the building unit assembly into position in the building such that each level of the building includes a predetermined number of units; connecting adjacent cells in each level to each other; and connecting a cell in one level to a corresponding cell in at least one adjacent level vertically above or below the one level.

The method may further comprise: constructing at least one core wall (core); and connecting units adjacent the core to the core, configured such that vertical loads between adjacent levels are transmitted primarily through the building unit assembly and lateral loads are transmitted to the core.

The method may further comprise: attaching structural frame segments to at least one side wall of a building unit to form a building unit assembly; and stacking the building unit assemblies to form levels of the building such that structural frame segments in one level are vertically aligned with structural frame segments in at least one adjacent level whereby substantially all vertical loads of the building unit assemblies are transmitted through the structural frame segments.

In some embodiments, lateral loads are carried by the building units.

In some embodiments, lateral loads are carried by more than one core wall.

The method may further comprise the steps of: top and bottom connecting plates are provided at the top and bottom of each structural frame segment, and the top and bottom plates of the structural frame segments vertically adjacent to each other are connected together with fastening means.

In some embodiments, the structural frame segments are attached to the side walls of the building units such that when the building unit is placed laterally adjacent to another structural frame segment in a predetermined relative alignment, the structural frame segments of a building unit assembly are positioned side-by-side with the structural frame segments on the laterally adjacent building unit assembly; and the method may include the step of joining together structural frame segments positioned alongside one another.

In some embodiments, the step of connecting a cell in one level to a corresponding cell in a vertically adjacent level comprises the steps of: the top of the structural frame segment in the lower level is connected to the bottom of the structural frame segment in the higher level.

The method may comprise the steps of: mounting a top connection plate and a lower connection plate on the top end and the lower end of the column element, respectively; and connecting together the top webs of the structural frame segments positioned side-by-side with one another.

The method may comprise the steps of: connecting the top connecting plate of the structural frame segments positioned side by side to each other to one of the lower connecting plates of the structural frame segments positioned side by side to each other in the immediately upper level.

The method may comprise the steps of: the other of the lower connector plates is clamped between vertically adjacent top connector plates by means of elongate clamping bars.

In another aspect, the present invention provides a building having a plurality of levels, the building comprising: a plurality of building unit assemblies, each of said plurality of building unit assemblies being structurally self-supporting and having at least one side wall, a floor and a roof; and structural frame segments attached to the at least one side wall of the building unit assemblies, a plurality of groups of the building unit assemblies being stacked to form a level of the building and wherein the building unit assemblies are stacked such that structural frame segments in one level are vertically aligned with structural frame segments in at least one adjacent level whereby substantially all vertical loads are transmitted through the structural frame segments and lateral loads are carried by the building unit assemblies.

In some embodiments, the building may further comprise a core and the plurality of groups of building unit assemblies can be arranged around and connected to the core such that vertical loads between adjacent levels are transmitted primarily through the building unit assemblies rather than through the core.

In some embodiments, the building further comprises one or more elongate connecting means extending between the top of a corresponding first structural frame segment attached to a building unit in one level to the top of a vertically aligned second structural frame segment attached to a building unit assembly in another level to enable the top of the first building element to be connected to the top of the second structural frame segment by said elongate connecting means.

In some embodiments, the plurality of levels includes at least one building unit assembly placed in a first orientation and at least one second building unit assembly placed orthogonally to the first orientation, such that the building unit assemblies in the first and second orthogonal orientations act as bracing (braced) to carry lateral loads.

In some embodiments, the ends of the column elements have mounting means attached thereto, whereby the mounting means and the structural frame segment can be attached to adjacent plates of the structural frame segment vertically above or below said one structural frame segment.

In some embodiments, the mounting means comprises a top connecting plate and a lower connecting plate, and the position of the structural frame segments relative to the building units to which they are connected is such that: in a building stage at least some of the structural frame segments of adjacent building unit assemblies are located side by side in pairs with each other and wherein at least one lower connecting plate of a structural frame segment of another building unit assembly stacked above one of the adjacent building unit assemblies overlies at least a portion of the top connecting plate of the pair of structural frame segments, whereby the at least one lower connecting plate is connectable to at least a portion of the upper connecting plate of the pair of structural frame segments, thereby connecting the adjacent building unit assembly and the other building unit assembly together.

In some embodiments, the mounting means comprises a top connecting plate and a lower connecting plate, and the position of the structural frame segments relative to the building units to which they are connected is such that: in a level of the building at least some of the structural frame segments of adjacent building unit assemblies are located side by side with one another in pairs, the arrangement of the connecting plates being such that: for vertically aligned pairs of structural frame segments, at least three of their connecting plates can be connected together.

In some embodiments, the building may further comprise: first connecting means for connecting adjacent building unit assemblies within one level to each other; and second connecting means for connecting a building unit assembly within one level to an adjacent building unit assembly level adjacent to said one level.

In another aspect, the invention provides a building having a plurality of levels, at least some of the levels including a plurality of self supporting building units, each of the plurality of self supporting building units including a structural frame segment connected thereto, the structural frame segment being adapted to support vertical loads of another level above the level, wherein: the building comprises at least one higher level and one lower level, wherein the structural strength of the frame segments of the building units at the lower level is greater than the structural strength of the corresponding frame segments in the higher level.

In some embodiments, the building comprises a set of higher levels and a set of lower levels, wherein the structural strength of corresponding structural frame segments within the set of lower levels is substantially equal and the structural strength of corresponding structural frame segments within the set of higher levels is substantially equal.

In some embodiments, the structural strength of a structural frame segment in a set of lower levels can be greater than the structural strength of a corresponding frame segment in a set of higher levels.

The structural frame segments are preferably located externally of the self supporting building units.

In some embodiments, the structural frame segment comprises column elements attached to the self supporting building units.

In some embodiments, the building units are arranged in a level so as to define spaces between adjacent self supporting building units in which the structural frame segments are located.

In some embodiments, the spaces between vertically aligned pairs of adjacent self supporting building units are of substantially the same width.

In some embodiments, the spaces between all adjacent self supporting building units are of substantially the same width.

In some embodiments, the structural frame members all have substantially the same width transverse to the spaces between adjacent self supporting building units in which they are located.

In some embodiments, the relative strength difference between the two structural frame members is provided by varying at least one of the following factors:

a relative wall thickness of the structural frame member;

the relative depth of the structural frame members measured along the space between adjacent self supporting building units.

In a further aspect, there is provided a structural frame segment for fitting to a self supporting building unit, the structural frame segment comprising: at least one load bearing column element; mounting means on each end of the structural frame segment for securing the structural frame segment to another similar self supporting building unit or building element.

In some embodiments, the mounting means comprises an engagement portion for engaging a matingly shaped engagement portion of the vertically aligned structural frame segment, in use.

In some embodiments, the mounting means is a connection plate attached to the end of the column element.

In some embodiments, the at least one column element comprises any one of a steel column or a concrete column.

In use, the position of the column element relative to the building unit to which it is connected is such that: in one stage of the building at least some of the column elements of adjacent building units are located side by side with each other in pairs, and wherein at least one lower connecting plate of a column element of another building unit stacked on top of one of the adjacent building units overlies at least a portion of the top connecting plates of the pair of column elements, whereby the at least one lower connecting plate is connectable to at least a portion of the top connecting plates of the pair of column elements, thereby connecting the adjacent building unit and the other building unit together.

In some embodiments, the position of the column element relative to the building unit to which it is connected is such that: in a level of a building at least some of the column elements of adjacent building units are located side by side with one another in pairs; the connection plate is configured such that: for vertically aligned pairs of column elements, at least three of their connecting plates can be connected together.

In some embodiments, the structural frame segment has a mounting means shaped to match the mounting means of a horizontally adjacent structural frame segment in use.

In some embodiments, the structural frame segment comprises a plurality of column elements coupled by a means to distribute load between at least pairs of the plurality of columns.

In some embodiments, guide surfaces are included to facilitate alignment with other building components.

In some embodiments, the guide surface comprises at least a portion of a surface of the mounting device.

In some embodiments, the guide surface comprises at least a portion of a column element.

In some embodiments, the mounting device comprises an angled guide surface for guiding the mounting device into correct alignment with a correspondingly shaped mounting device in use.

In some embodiments, the guide surface comprises a vertically extending portion which, in use, enables the vertical alignment of the structural frame segment relative to another building or the like to be adjusted by sliding the guide surface against the building element.

In some embodiments, the mounting device includes at least one mounting plate that includes a tapered portion (taper) to provide an angled guide surface.

In some embodiments, the mounting means comprises a generally trapezoidal plate which, in use, provides a tapered guiding surface for the corresponding structural frame section in horizontal alignment.

In some embodiments, at least one column element extends in a substantially perpendicular direction from a surface of the mounting plate and is positioned such that: at least a portion of the surface of the column element is substantially aligned with the apex of the trapezoidal top plate forming part of the guiding surface of the mounting device and extends away from the trapezoidal top plate such that said portion of the surface of the column element provides a continuation of said guiding surface.

In another aspect, the present invention provides a method of constructing a building unit for use in constructing a building having a plurality of levels, the method comprising: (a) the method comprises the following steps Constructing a self-supporting unit comprising a floor, a roof and at least one side wall to thereby define an interior of the unit and an exterior of the unit; (b) the method comprises the following steps Attaching at least one frame segment to the exterior of the unit so as to structurally support, in use, a building unit assembly arranged above the building unit assembly.

The method may further comprise: (c) the method comprises the following steps Performing a stress relief step prior to step (b).

The step (a) may further comprise: constructing a self-supporting unit with a jig or clamp; and step (c) may comprise: releasing the clamping force applied by the clamp or vice.

Step (c) may include: thermally conductive stresses in the self-supporting unit are dissipated.

In some embodiments, step (a) may comprise one or more of the following construction steps:

forming a floor from a plurality of floor panels;

forming at least one wall from a plurality of wall panels;

forming a frame from a plurality of frame members;

forming a roof from a plurality of roof panels;

attaching at least one of a wall, floor, or roof to the frame;

attaching at least one wall or wall member floor;

attaching a roof or at least one roof panel to at least one wall.

In some embodiments, the frame segments comprise structural frame segments according to an embodiment of an aspect of the present invention.

The method may include: at least one datum point is defined on the exterior of the self-supporting unit with reference to one or more structural frame segments.

The method may further comprise: arranging at least a part of the interior of the building unit with the at least one reference point as a reference.

The method may further comprise: attaching at least one facade element to the building unit assembly with the at least one datum as a reference.

In some embodiments, the method may comprise: the measurements are transferred from the at least one reference point to the interior of the self-supporting unit.

In another aspect, the invention includes a method of laying out a building having a plurality of levels, the method comprising:

designing the layout of the floor;

defining a structural network of pillars common to a plurality of vertically adjacent levels;

a plurality of cells in each level are defined between columns of the network of columns such that the network of columns is located in spaces between horizontally adjacent cells.

In some embodiments, the method further comprises: the layout is adjusted to fit the space between the grid and horizontally adjacent cells.

The method may further comprise: a structural network of pillars common to all levels is defined.

In some embodiments, the method further comprises: a plurality of cylinder nets corresponding to the plurality of groups of levels is defined.

The method may further comprise: the transfer structure is positioned between groups of levels forming a plurality of groups.

In another aspect, the present invention provides a method for constructing a building; the method comprises the following steps: laying out a building using a method according to an embodiment of another aspect of the invention, and manufacturing a plurality of self supporting building units of the lay out, wherein each unit has associated structural support segments attached thereto, the structural support segments being aligned with a defined network of columns.

In some embodiments, the method further comprises: at least one in situ component of the building is constructed.

In some embodiments, the method further comprises: stacking a plurality of self supporting building unit assemblies in a defined configuration with the in situ components of the building and connecting self supporting building unit assemblies together and to self supporting building unit assemblies.

In some embodiments, the method further comprises: prior to construction of the building, a plurality of self supporting building unit assemblies are positioned in a relationship to each other as defined by the layout.

In some embodiments, the method may further comprise: performing any of the following steps on the self supporting building unit assembly so positioned:

checking tolerances between at least some of the components of adjacent self supporting building unit assemblies;

verifying correct vertical and/or horizontal alignment between structural support segments of adjacent self supporting building unit assemblies;

arranging at least a portion of an interior of a self supporting building unit assembly;

temporarily connecting an auxiliary member between at least two self supporting building unit assemblies;

disconnecting the temporarily connected auxiliary elements from the self supporting building unit assembly;

mounting a facade or cladding member to a self supporting building unit assembly.

Another aspect of the invention includes, but is not limited to, the aforementioned buildings, building unit assemblies, building units, structural support segments and components made or assembled according to or used in the methods described herein.

According to the present invention there is provided a method of constructing a building having a plurality of levels using a plurality of building unit assemblies, wherein each building unit assembly is structurally self-supporting and has side walls, a floor and a roof, the method comprising the steps of: lifting the building unit assembly into position in the building such that each level of the building includes a predetermined number of units; connecting adjacent cells to each other in each hierarchy; and connecting a cell in one level to a corresponding cell in an adjacent level vertically above and below the cell.

The present invention also provides a method of constructing a high-rise building having a plurality of levels using a plurality of building unit assemblies, wherein each building unit assembly is structurally self-supporting and has side walls, a floor and a roof, the method comprising the steps of: constructing a core wall; lifting the building unit assembly into position in the building such that each level of the building includes a predetermined number of units; and connecting units adjacent the core to the core, configured such that vertical loads between adjacent levels can be transmitted primarily through the building unit assembly and lateral loads transmitted to the core through walls, floors, roofs or other rigid members or through the use of bracing means.

The present invention also provides a method of constructing a high-rise building having a plurality of levels using a plurality of building unit assemblies, wherein each building unit assembly is structurally self-supporting and has side walls, a floor and a roof, the method comprising the steps of: attaching the structural frame segment to a side wall of the building unit assembly; stacking the building unit assemblies to form levels of the building such that the structural frame segments in one level are vertically aligned with the structural frame segments in at least one adjacent level whereby substantially all vertical loads are transmitted through the structural frame segments and lateral loads are carried by building unit assemblies placed orthogonally to one another to act as supports or by other rigid members such as core walls.

Preferably, the method further comprises the steps of: top and bottom connecting plates are provided at the top and bottom of each structural frame segment, and fastening means are used to connect together the top and bottom plates of the structural frame segments that are vertically adjacent to each other.

Preferably, the method further comprises the steps of: the structural frame segments of building unit assemblies which are laterally adjacent to one another are positioned such that the top and bottom plates of the structural frame segments are laterally adjacent to one another, and the top and bottom plates of the structural frame segments which are laterally adjacent to one another are connected together using fastening means.

Preferably, the method further comprises the steps of: providing complementary portions on the roof panels of building unit assemblies laterally adjacent to each other and wherein the method includes the steps of: providing first and second bottom panels, respectively, of the structural frame segments of the building unit assemblies laterally adjacent one another and positioning the first bottom panel over the complementary portion whereby the fastening means join the top and bottom panels in the vertical and lateral directions.

Preferably, the method comprises the steps of: connecting the lower end of an elongate connecting rod to a first top panel of a structural frame segment of a first building unit assembly stacked vertically below a second building unit assembly and connecting the top end of the connecting rod to a second top panel of the second building unit assembly, thereby clamping the first and second top panels together.

The invention also provides a building having a plurality of levels, the building comprising: a plurality of building unit assemblies, each of which is structurally self-supporting and has side walls, a floor and a roof, a plurality of sets of building unit assemblies being stacked to form a level of a building; first connecting means for connecting adjacent building unit assemblies within one level to each other; and second connecting means for connecting a building unit assembly within one level to an adjacent building unit assembly level adjacent to said one level.

Preferably, the building is characterised in that the building has no other structural framing than that provided by the interconnected building unit assemblies.

The invention also provides a building having a plurality of levels, the building comprising: a plurality of building unit assemblies, each of the plurality of building unit assemblies being structurally self-supporting and having sidewalls, a floor and a roof; a core about which groups of building unit assemblies are stacked to form a level of a building; and connecting means for connecting units adjacent a core to the core, arranged such that vertical loads between adjacent levels are transmitted primarily through the building unit assembly rather than through the core.

The invention also provides a building having a plurality of levels, the building comprising: a plurality of building unit assemblies, each of the plurality of building unit assemblies being structurally self-supporting and having sidewalls, a floor and a roof; and structural frame segments attached to the side walls of the building unit assemblies, a plurality of groups of building unit assemblies being stacked to form a level of the building and wherein the building unit assemblies are stacked such that structural frame segments in one level are vertically aligned with structural frame segments in at least one adjacent level whereby substantially all vertical loads are transmitted through the structural frame segments and lateral loads are carried by building unit assemblies placed to act as supports or by other rigid members such as concrete or steel cores.

Preferably the building includes connecting means for connecting a structural frame segment of a building unit assembly in one level to an adjacent structural frame segment of a building unit assembly in an adjacent level.

Preferably the ends of the structural frame segments have connecting plates connected thereto, whereby the plates and structural frame segments can be connected to adjacent plates of the structural frame segment located vertically above or below the one plate.

Preferably, the panel of said one structural frame segment is connectable to the panel of a structural frame segment laterally adjacent to said one structural frame segment.

Preferably, vertically aligned adjacent structural frame segments have plates provided with protrusions and recesses that are complementary to each other to allow for precise alignment of the posts when stacked.

Preferably the top or bottom plates of the first and second laterally adjacent structural frame segments comprise complementary portions having respective bolt holes therein whereby the bottom or top plate of a third structural frame segment vertically adjacent the first or second structural frame segment is located above the complementary portions and has bolt holes aligned with the bolt holes in the complementary portions whereby the plates of the first, second and third structural frame segments can be clamped together using bolts.

Preferably, the top plate of the structural frame segment comprises said complementary portion.

Further preferably, the top plate comprises said recess and the bottom plate comprises said protrusion.

In some embodiments, the structural frame segments are provided with a top connecting plate and a lower connecting plate, and wherein the position of the structural frame segments relative to the building unit assemblies to which they are connected is such that: in a level of the building at least some of the structural frame segments of adjacent building unit assemblies are located side by side in pairs with each other and wherein at least one lower connecting plate of a structural frame segment of another building unit assembly stacked above one of the adjacent building unit assemblies overlies at least a portion of the top connecting plate of the pair of structural frame segments, whereby the at least one lower connecting plate is connectable to at least a portion of the top connecting plate of the pair of structural frame segments to connect the adjacent building unit assembly and the other building unit assembly together.

In some embodiments, the structural frame segments are provided with a top connecting plate and a lower connecting plate, and wherein the position of the structural frame segments relative to the building unit assemblies to which they are connected is such that: in a level of the building at least some of the structural frame segments of adjacent building unit assemblies are located side by side with one another in pairs, the arrangement of the connecting plates being such that: for vertically aligned pairs of structural frame segments, at least three of their connecting plates can be connected together.

Preferably, the two top connecting plates or the two lower connecting plates are complementarily shaped so that the third of the at least three connecting plates is located above the two plates or below the two plates.

Preferably, the connection plates include bores positioned such that the bores are aligned in the at least three connection plates and fasteners can pass through the bores to connect the three connection plates together.

Preferably, the pairs of upper and lower connecting plates comprise first and second formations which interlock with one another.

Preferably, the formations comprise projections and recesses.

Preferably, the protrusion is on the underside of the upper web and the recess is on the upper side of the lower web.

In some embodiments, the lateral loads can be carried by the floor and roof of the building unit, and wherein at least some of the structural frame segments comprise at least one hollow column element; the building further comprises elongate connecting means extending through at least some of the hollow column elements such that the top of a structural frame segment in one level can be connected by the elongate connecting means to the top of a structural frame segment in an adjacent level of the building.

Drawings

Exemplary embodiments of the invention will now be further described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

figure 1 is a schematic perspective view of a building unit assembly of an embodiment of the present invention;

fig. 2A to 2E show building unit assemblies of embodiments of the invention constructed using different building materials;

fig. 3A is a schematic plan view of two building unit assemblies spaced from each other;

fig. 3B is a schematic plan view showing two adjacent building unit assemblies connected together;

fig. 4A to 4D are schematic plan views illustrating different plan shapes for the building units;

fig. 5A to 5G are schematic views showing building unit assemblies stacked in various ways to build differently shaped high rise buildings;

figure 6 is a schematic side view of a twenty-high level building;

FIGS. 7A, 7B and 7C are schematic isometric views of a building having a core wall;

FIG. 8 is a schematic isometric view of a building having distributed core walls;

figure 9 is a schematic side view of a building showing how column elements can vary in size according to the height within the building;

figure 10 is a schematic isometric view of a five level high rise building;

fig. 11A to 11E show cells in each hierarchy level;

FIG. 12 is a more detailed schematic diagram showing the interconnection of units within one level of the building;

fig. 13A is a floor plan view of an apartment building;

13B, 13C, 13D and 13E are typical apartments in which the units of the present invention are used;

14A and 14B illustrate a lower floor level and a higher floor level in a hotel constructed in accordance with the present invention;

fig. 14C is a more detailed view of a building unit assembly suitable for use in the building of fig. 14A and 14B;

FIG. 15A is a floor plan layout of a building having residential and office arrangements;

FIG. 15B shows a possible arrangement of units for the residential portion of the building of FIG. 15A;

FIG. 16 is a schematic cross-sectional end view showing further details of the building unit assembly;

FIG. 17 is a schematic perspective view of one form of a lower mounting block;

FIG. 18 is a plan view of the lower mounting block;

FIGS. 19 and 20 are right angle side views of the lower mounting block;

FIG. 21 is a schematic perspective view of an upper mounting block;

FIG. 22 is a plan view of the upper mounting block;

FIGS. 23 and 24 are right angle side views of the upper mounting block;

figure 25 is an isometric view showing the interconnection of vertically adjacent building unit assemblies;

figure 26 is an exploded isometric view showing vertically adjacent and horizontally adjacent building unit assemblies;

figure 27 is an exploded side view showing interconnection of the mounting blocks of four building unit assemblies;

figure 28 is a more detailed schematic end view showing the vertical interconnection of the mounting blocks of two building unit assemblies;

figure 29 is a more detailed schematic side view of the horizontal interconnection of the mounting blocks of two building unit assemblies;

figure 30 is a more detailed schematic end view showing the interconnection of the mounting blocks of two building unit assemblies using elongate connecting members;

fig. 31 and 32 are schematic views showing the orientation of the connecting members during lifting of the building unit assembly;

figure 33 is a schematic side view of a four-storey building;

FIG. 34 is a top plan view of the lower web;

FIG. 35 is an end view of the side plate;

FIG. 36 is a top plan view of another lower web;

FIG. 37 is a side view of the web shown in FIGS. 34 and 36;

FIG. 38 is a plan view of the upper connecting plate;

FIG. 39 is an end view of the upper link plate;

FIG. 40 is a cross-sectional view taken along line 24-24;

FIG. 41 is a side view of the top plate;

FIGS. 42 and 43 are more detailed exploded views of two formed structural frame segments;

fig. 44 is a schematic plan view of two building unit assemblies spaced from each other with the structural frame segments shown in fig. 42 and 43;

fig. 45 is a schematic plan view showing the building unit assemblies of fig. 44 connected together;

figures 46 to 50 schematically illustrate the manner in which the structural frame segments of figures 42 and 43 are interconnected;

FIG. 51 is a schematic exploded view showing the various components connected to one another;

FIG. 52 is a side view of the lower web;

FIG. 53 is a plan view of the lower mounting block;

FIG. 54 is an end view of the lower mounting block;

FIG. 55 is a plan view of an alternative upper attachment plate;

FIG. 56 is a side view of the upper connecting plate of FIG. 55;

FIG. 57 is an end view of the upper connecting plate of FIG. 55;

FIG. 58 is a plan view of an alternative upper mounting block;

FIG. 59 is a side view of the upper mounting block of FIG. 58;

FIG. 60 is an end view of the upper mounting block of FIG. 58;

FIG. 61 is a plan view of an elongated bolt;

FIG. 62 is an exploded end view of the bolt head;

FIG. 63 is a side view of the upper end of the bolt;

fig. 64 is an exploded side view showing the bolt head;

FIG. 65 is an exploded view showing the upper end of the shaft of the bolt;

fig. 66 and 66A are schematic perspective views illustrating an alternative connection technique for building unit assemblies;

FIG. 67 is an exploded side view showing the interconnection of the connector plates and blocks of four building unit assemblies in one embodiment; and

fig. 68 is a schematic side view showing some of the internal details of the building unit assembly and the manner in which the structural frame segments are connected to the building unit assembly;

figure 69 shows a plurality of roof panels for a building unit;

FIG. 70 is a cross-sectional view taken along line 37-37;

FIG. 71 is a cross-sectional view taken along line 38-38;

figure 72 is an exploded view of the improved building unit of the present invention;

fig. 73 is a schematic view showing the position of structural frame segments on the building unit assembly;

fig. 74 is a schematic side view of a building unit assembly adapted for use with the cantilever;

FIG. 75 is a schematic end view of six building unit assemblies;

fig. 76 is a schematic perspective view of a floor panel for the building unit of fig. 72 and 73;

figure 77 is a schematic cross-sectional end view showing further details of the improved building unit assembly;

FIG. 78 is a schematic cross-sectional end view showing further details of another modified building unit assembly;

fig. 79 is a schematic cross-sectional end view showing further details of a further improved building unit;

fig. 80 is a schematic cross-sectional end view showing further details of another modified building unit;

FIG. 81 illustrates a perspective view of an alternative mounting plate that may be used in embodiments of the present invention;

FIG. 82 illustrates a plan view of the mounting plate of FIG. 81;

FIG. 83 illustrates three building unit assemblies to be mounted together using the mounting plate of FIG. 82;

figures 84A to 84C illustrate the manner in which adjacent building unit assemblies are assembled together using the mounting plate of figure 82; and

fig. 85 shows the same portion of the structural frame segment shown in fig. 81 in more detail.

Detailed Description

In broad terms the inventors have realised that the building unit itself (depicting the interior space of the unit) can be considered separately from the structural framework of the unit, when implemented in a preferred form, both to make the design flexible and to improve ease of manufacture.

With regard to ease of manufacture, the building unit can be manufactured with a relative slack tolerance of about ± 20mm, which is relatively easy to achieve. The structural frame segments can be manufactured to tighter tolerances within about + -1 mm to provide an accurate framework for the building. The building unit and associated structural frame segment assembly can then be attached together as follows: the attachment means accommodates any inaccuracies of the building unit to form a building unit assembly having accurately positioned structural frame segments attached thereto for assembly into a building.

The preferred embodiment provides a stand-alone column system with a precisely sized column net to which all other building components are dimensionally referenced.

In alternative systems where the structural frame of the building forms part of the frame of the building, the integral unit needs to be manufactured to meet the tighter tolerances required for the frame, which is costly and complex.

With respect to design and flexibility, the design and manufacture of the structural frame segments is decoupled from the unit so that the designer can flexibly position the structural frame segments in a wide range of positions relative to the building unit. This allows for design flexibility which is not practically achievable if the structural frame of the building unit is built into the walls of the unit.

The unitized building system of the present invention can be used to construct buildings to be used for any purpose, including but not limited to residential, hotel, and office uses. The preferred embodiments are also suitable for high-rise applications, that is, for buildings with four or more stories above ground level.

The building unit assemblies are made according to the building layout to be formed. In the system of the present invention, the building designer is free to lay out the building in a conventional manner to meet the needs of the customer and the needs of the market. Next, a structural network of pillars common to a plurality of vertically adjacent levels is defined, and a plurality of cells in each level is defined. The cells are located between the columns of the column network, which, conversely, is located in the spaces between adjacent cells. The design of a building may require adjustment to divide into building units of variable width and length sized for transport and lifting by a crane into position on site. The building units may be prefabricated systems that use building finishing pieces (finishes) and aids to complete the structure of the building, ready for assembly on site.

As explained in more detail below, embodiments may have the following features: the length, width and height of the building units are different in each project; the building unit is capable of incorporating all the components of the building, including stairways, corridors and aids; constructing a building unit assembly within a production facility; the completed building unit assemblies are all transported to the site for assembly; lifting the building unit assembly to a proper position by a construction crane; since the facades and interior components can be connected to or fitted into the building unit assemblies prior to delivery, the effort to complete the building on site is minimal; specific bolted connections may be used to connect the building unit assemblies together; and each building unit is structurally self-supporting and may have structural frame segments connected thereto such that when connected together the building unit assembly including the structural frame segments forms vertical and lateral supports of the building.

Each building unit can be seen as a rectilinear box frame that is structurally independent and structurally self-supporting in terms of its own weight and the dynamic loads that it will carry.

The cells may be constructed from a variety of materials, including: a wood frame construction having plywood supports supporting walls, floor and roof panels; a steel frame truss construction using steel sections and profiled steel sheets for walls and roofs and rolled channel steel and profiled steel sheets or stringers for floors; and profiled steel sheet construction to construct the divider walls and roof sections, the rigidity of the walls and roof sections being sufficiently great that no additional cross braces are required, so that the steel sheet walls constitute a major part of the strength of the unit in a monocoque construction or system for use in the automotive and aerospace industries. Typically, the building unit is relatively strong in the longitudinal direction, i.e. along the plane of its walls, when compared to the transverse direction. By providing the support members in the lateral direction, the building unit can be made strong in the lateral direction. The support may be in the form of a frame-type support, a wall, a tension cable or other means. The strength of the building unit along its length can be used advantageously to provide support for lateral loads in the manner described elsewhere herein. In the transverse direction, transverse loads can be transmitted through the floor, roof and transversely extending walls transverse to the interior space of the building unit.

Fire protection can be achieved by using fire-resistant plasterboard linings for the interior walls and roof of the building unit.

Internal arrangements including painting, tiling, carpeting, and joinery may all be done, or may be done on-site in a "blank" stage. Facade elements, circulation corridors and stairways can also be incorporated into the building units prior to delivery or completed on site. As mentioned above, these components can also be accurately located by making position measurements from reference points associated with the structural frame segments rather than the building units.

The building unit may have more than four structural frame segments comprising structural steel or concrete column elements secured to the interior of the structural frame segments to carry the total load and to form the building structure in combination with the building unit. The column element is designed to carry the loads it is subjected to at locations within the structure. Additional structural supports may be included to distribute loads or increase stiffness, if desired. This can be seen as forming the exterior structure of the building unit which will be connected together with the exterior structure of adjacent units to form the load bearing structure of the building.

The external structure occupies an area outside of the interior space that the building unit may occupy, so that there is no conflict between the two in terms of constructability and assembly. The structural area between building units typically ranges from 100mm to 150 mm. This area is the area where all the structural frame sections are located and the area where all the connections that lock the whole building together are made.

The advantages of this structure in terms of constructability are: due to the precise placement of the structural frame segments, the building units, the external structure of the structural frame segments including the building unit assembly, and the facade elements can be temporarily aligned in the production facility after fabrication, even locked together in the position they will occupy in the multi-level structure. This process facilitates checking tolerances to ensure ease of assembly and quality control in the field. It also allows completion on ground level, which is more cost effective and less dangerous than it would be done in a regular elevated position as in the high-rise building option. This makes it easier to check, manage and obtain the tolerances of the building and facade at the manufacturing stage, rather than at the assembly stage.

The size of the structural frame segments or column elements thereof may increase as the building height and/or load bearing requirements increase. The elements are dimensioned to suit the position of the elements within the structure so that building unit assemblies at the bottom of the building may have larger column elements connected thereto than building unit assemblies at the top. However, the building unit may remain unchanged when it is designed to only support itself.

The building unit transmits lateral loads through the panels of the walls, roof and floor to the stabilising members or supports. These stabilizing members may be in the form of other units placed in an opposite direction to the main body of the unit. Depending on the height of the building, these stabilizing members may be framed core walls within the selected unit or conventional concrete or steel framed core wall systems. Vertical loads within the building unit are transferred through the side walls of the building unit to the structural frame segments connected to the side walls.

The building unit in its most basic form can be viewed as a box frame supported at four points with open ends. This structure is light and highly resistant to wind and seismic loads. This structure is also sufficiently weather-adaptive to allow transport and erection without damaging the internals by water.

Since all the columns are in the outer 100mm to 150mm inter-column region of the unit face, the interior of the building unit is unaffected by the structural members. Even if the height of the building is as high as 50 floors, the area remains the same. This is achieved by increasing the depth and strength of the pillars while maintaining the width of the pillars.

For some structures, typically low to mid level structures, lateral loads can be eliminated by turning some building units substantially perpendicular to the direction of other building units. This can be determined by laying out the building. Alternatively, the ends of the unit may be stiffened by using heavier frames and/or supporting additional walls or introducing additional members to accommodate the loading conditions of each particular building or site. It is also possible to add frames to elevators and stairways to carry the lateral loads. The elevators and stairways may be combined into building unit assemblies or constructed separately.

For higher level structures beyond levels 12 to 15, a more conventional support system using in situ concrete core is advantageous. In the case where an in situ concrete core is used as the main support member, the core will be partially or fully constructed prior to installation of the fabricated building unit assembly.

For very tall buildings, it may be necessary to introduce concrete or steel transfer structures that require realizability and economy, or to accommodate changing loading or support requirements dictated by building design and site conditions.

On steel core structures this effectively splits a high rise building into more than two stacks of units carried by concrete. In the case of a concrete core, the concrete core may also be used as a support member by using a transfer structure that transfers vertical loads back to the core, thereby reducing the size of the structural frame segments connected to the building units, effectively reducing the building into a series of smaller structures. For example, a 20 level building may incorporate three transfer structures, reducing the effective height of the structural frame segments to that required by a five level building.

The transfer structure may be connected to the structure of the building unit assembly itself in order to assemble the transfer structure with the building unit assembly.

Alternatively, the transfer structure may be provided as a separate steel structure or a concrete structure, as the case may be.

As mentioned above, the building unit assemblies may have dimensions that vary according to need and transportation constraints. Typically, however, each building unit assembly may have a width of about 2 to 5m, a length of 10 to 28m and a height of 2.7 to 3.3 m.

It will be further understood that in a building, building unit assemblies of different sizes and shapes may be configured to generate the required floor plan areas for the available space of the building. The side wall of the building unit may have an opening formed therein for doors, windows or the like. Corridors and balconies, etc. may also be added.

Figure 1 shows a schematic view of a building unit assembly 2 constructed in accordance with an embodiment of the invention. The building unit assembly 2 comprises a building unit comprising two side walls 4 and 6, a floor 8 and a roof 10 to which structural frame segments in the form of column elements 14, 16, 18 and 22 are attached.

In the illustrated configuration, the ends 12 and 14 are open, but may be closed as desired. As will be explained in more detail below, the side walls 4 and 6, floor 8 and roof 10 are of a robust construction to enable the building unit assembly 2 to be self-supporting during transport and lifting. The building unit assembly 2 is also capable of withstanding loads applied to it in use, such as internal assembly loads and dynamic loads. As explained in more detail below, the building unit assemblies 2 can be manufactured in a factory remote from the site where the building in which the units 2 are used is to be erected (e.g. in the factory of other production facilities). Manufacturing building unit assemblies as industrial products helps to save costs, save time, and achieve better manufacturing tolerances for the finished units.

In the illustrated arrangement, the building unit assembly 2 has four column elements 16, 18, 20 and 22 connected to the side walls, the elements 16 and 18 being connected to the side wall 4 and the elements 20 and 22 being connected to the side wall 6. As will be explained below, the function of the structural frame segments is to provide mounting points for the building unit assemblies 2 and also to carry vertical loads when the building unit assemblies are stacked on top of each other. The members 16, 18, 20 and 22 include respective lower mounting devices 24 and respective upper mounting devices 26. The upper mounting device 26 can form an attachment point for a "hoisting cable" during the transport and construction phase. Also, as will be explained in more detail below, the components 24 and 26 can be used to couple adjacent building unit assemblies 2 to one another in the finished building.

The building unit 2 itself may be constructed from a variety of materials. Figure 2A diagrammatically shows the arrangement in which the side walls 4 and 6 and roof 10 are wood frames with plywood cladding. The floor 8 may be a profiled steel sheet. Fig. 2B shows an alternative arrangement in which the building unit 2 has its side walls and roof supported as steel frames and the floor 8 is profiled steel sheet. Figure 2C shows an alternative arrangement in which the side walls and roof are in the form of framed trusses with profiled steel sheet supports for supporting the side walls and roof and floor.

Fig. 2D shows an alternative arrangement in which the building unit has side walls, floor and roof all made of profiled steel sheet. Fig. 2E shows an alternative arrangement in which the building units are formed from glass fibre reinforced concrete (GRC) or other composite panels, the floor 8 being of profiled steel sheet, GRC or composite construction.

Fig. 3A is a schematic plan view showing two building unit assemblies 2A and 2B positioned adjacent to each other. As can be seen in fig. 3A, the structural frame segments 16 and 18 on the side wall 4 are offset in position relative to the structural frame segments 20 and 22 on the side wall 6. This arrangement allows the structural frame segments to be positioned adjacent to each other in the final installed position of the building unit assemblies 2A and 2B as shown in fig. 3B.

It will be appreciated that there is a gap 28 between adjacent side walls 4 and 6 of the assembled building unit, as shown in figure 3B. A gap or inter-post region 28 is defined by the width of the post and provides space to accommodate vertical structural support. Furthermore, the inter-post regions 28 also contribute to acoustic and thermal isolation between adjacent cells.

The upper mounting device 24 and the lower mounting device 26 are schematically shown in fig. 1-3. As will be explained in more detail, the upper mounting means may be of different types, as may the lower mounting means. Several embodiments will be described in more detail below.

It should be understood that similar units may be stacked in various arrangements as desired. The cells may also be configured such that the ends of the cells are adjacent one another, and in that case, the structural frame segments (not shown) in fig. 3A and 3B are provided on the end walls 12 or 14, so that the cells can be connected end-to-end (rather than side-by-side) in a manner similar to that shown in fig. 3A and 3B. Since the mounting means 24 and 26 project below the floor 8 and above the roof 10 respectively, the mounting means 24 and 26 also form gaps between vertically stacked building units, and these gaps have a similar function in improving fire ratings, sound and thermal insulation between building units in different levels in the building, etc.

The mounting means 24 and 26 serve to interconnect adjacent building unit assemblies and the combination of self supporting building units and interconnected structural frame segments can preferably constitute the sole framework of the building. Depending on the layout of the building units, the height of the building and the relevant site conditions, additional stabilising members or supports can be added.

The building unit 2 shown in fig. 1 to 3 has a rectangular shape in plan view. Fig. 4B, 4C and 4D show three of many alternative planar shapes of cells. More specifically, FIG. 4B shows a cell having a trapezoidal plan view; FIG. 4C shows a cell having a wedge (or trapezoidal) planar shape; FIG. 4D shows a cell having three orthogonal straight sides and one curved side. Other shapes are also possible. It will be appreciated that the units can be interconnected in a similar manner to that shown in figures 2 and 3.

The building unit assemblies 2 can be stacked in various ways to build buildings having different shapes. Figure 5A diagrammatically shows four units 201, 202, 203, 204 stacked on top of each other to form a four-storey building 30. Fig. 5B shows a four level building 32 with multiple pairs of units forming each level, wherein a pair of units 203 on the third level actually becomes orthogonal to levels 1, 2 and 4, thereby providing a cantilevered arrangement for units 2.3 and 2.4 relative to the units below it.

Figure 5C shows a four-storey building 38 having two columns of wedge-shaped units 40 and 42, the two columns of wedge-shaped units 40 and 42 being of different lengths to the central column of units 44 and being mounted offset with respect to the central column of rectangular units 44 to form a more complex shaped building. Fig. 5D shows a building 46 in which columns 50 and 52 of transverse units are placed on either side of a central group 48 of rectangular building unit assemblies, some of the units (e.g. 50.4 and 50.5) in the upper units having rounded ends to form a building with a curved appearance. Fig. 5E shows a five-level building 54 constructed from columns of units having a trapezoidal plan shape. Fig. 5F shows a building 55 in which there are six rows of building unit assemblies 57.1 to 57.6 stacked side by side and two rows 59.1 and 59.2 stacked end to end in the building 55. The combination of columns in orthogonal directions provides support for the building.

Fig. 5G shows another building 61 in which three columns of building unit assemblies 61.1, 61.2, 61.3 are arranged such that each column is orthogonal to its adjacent column, again providing inherent support due to the orientation of the building unit assemblies.

Figure 6 diagrammatically shows a twenty-level building 56 with a central concrete core 58. The core 58 typically comprises an elevator shaft in a conventional manner. The levels of the building are constructed from building unit assemblies that are manufactured off-site and lifted into position. In a higher rise building of this size, the core wall 58 helps to support the building. In the illustrated configuration, building 56 includes three transfer structures 60, 62, and 64 supported by core 58. The transfer structure may be formed of a reinforced concrete structure or a steel structure connected to the core wall. The primary function of the transfer structures 60, 62 and 64 is to transfer vertical loads from the building unit assemblies of the five levels stacked above them to the core wall so that the overall vertical load of the building does not have to be transferred through the structural frame segments assembled to the individual building units below. In this way, the size of the structural frame segments need not be so large that the overall vertical load of the building is carried by the lowermost structural frame segment in the structure. However, the initial calculations have surprisingly shown that for buildings up to 50 levels in height, it is not necessary to use a transfer structure as mentioned above. Calculations also confirm that the gaps or inter-column regions 28 between building units can remain constant throughout the building and that the depth, wall thickness, material strength or grade of the column elements of the structural frame segments can vary to provide sufficient strength depending on their location within the overall building.

Table 1 below is a summary of typical values of the amount of axial compression applied to a structural frame segment as a function of the height of the building. The table includes data for the dimensions of the pillars of different widths shown.

In table 1, the "floor" column indicates the floor number occupied by the unit when counted from the top of the building. Thus, level 1 is the top level, and in a 50-level building, level 50 is the bottom level. The "axial compression" column lists the load on each column of the building unit assembly in that storey. Column designation "column size": the cross-sectional dimensions and wall thickness of the column required to support the identified load are for each of 100mm, 125mm and 150mm column widths. For rectangular columns, the dimensions width x depth are given in millimeters and the wall thickness is given in mm. For a square column, only one wide wall length and thickness is indicated. Here, four measurements are given, representing the dimensions of the column element formed by the I-beam. Thus, 125 × 250 × 40 × 25 indicates the use of such an I-beam: it has a total width of 125mm along its end flanges and a width of 250mm along its central axis. The end flanges were 40mm thick and the central web 25mm thick.

The last set of columns labeled "column capacity" represents the load capacity of the RHS and SHS having the dimensions specified in the corresponding "column size" column when made from 450MPa steel and fitted with a mounting component made from 350MPa steel.

As can be seen from table 1, the load capacity of the column elements is greater in building unit assemblies at lower levels of the building because the column elements need to absorb or transmit higher vertical loads. Conversely, this means that higher levels may use less strong column elements to avoid unnecessary weight and cost in the roof of the building. For convenience, groups of levels within a building may be provided with columns of the same strength, rather than having different columns in each level. The relative increase in strength is provided by increasing the pillar size or wall thickness at lower levels, such as those set forth in table 1.

The column element may be in the form of a reinforced concrete column which is firmly attached to the side wall of the building unit. Alternatively, the column elements may comprise steel column elements screwed or welded to the side walls. Other materials may also be used.

It is assumed in table 1 that a single column element is used in each structural frame section, but more than one column element may be used. In this case separate components may be used to balance the load between the column elements. This load sharing function may be performed by mounting means attached to the column element or by a separate dedicated structure, such as a support between a plurality of column elements. In some cases, the structural frame segments may include wide posts such as blade columns or even walls to support the required vertical loads. In either case, the mechanism for operation will be similar to that of the narrow column element described in connection with the preferred embodiment.

While this flexibility is mastered, the concept of vertical alignment should be considered broadly, i.e., vertical alignment need only be accurate enough to transfer vertical loads to the aligned structural support segments to the extent needed. For example, for narrow structural frame segments with small mounting devices, the vertical alignment requires relatively tight tolerances so that the vertical load from the upper structural frame segment can be adequately supported by the lower structural frame segment. However, the degree of vertical alignment (in the direction along the column gap) need not be so exact as long as vertical loading can be transferred when the wall-shaped structural frame segment abuts the column-shaped structural frame segment (or several columns similar to the structural frame segment).

Fig. 7A is a schematic isometric view of a set of five levels 70, 72, 74, 76 and 78 that can form part of the building 56 shown in fig. 6. The orientation of the building units 2 making up the levels 70, 72 … 78 can be varied as required.

Figure 7B shows a building 63 with a central core 58 but with the rows of building units in a different configuration. The building units are arranged around a core 58. Fig. 7C shows another building 65 which is again constructed from rows of building units but this time supported by side core walls 67.

Fig. 8 illustrates a building 80, the building 80 having a distributed auxiliary configuration instead of the central core wall 58 of the configuration shown in fig. 6 and 7. In this arrangement, the building 80 has five levels 82, 84, 86, 88 and 90 and the components making up the distributed assistance arrangement can be built in the building units making up each level. In the illustrated configuration, there is a lift core 98, two stairwells 100 and 102, and a duct core 104. These components are separate from each other and, as can be seen in plan view, the arrangement of these ancillary components therein increases the overall stability of the building by using heavier structural components as the individual vertical ducts are distributed over a wider area than would be possible using a single central arrangement.

Fig. 9 is a schematic side view of a multi-storey building wherein levels 1 to 5 are made from building unit assemblies indicated by reference numeral 112; levels 6 to 10 are made from building unit assemblies as indicated by reference numeral 114; the levels 11 to 15 are made from building unit assemblies denoted by reference numeral 116; and the levels 16 to 20 are made from building unit assemblies as indicated by reference numeral 118. The load bearing capacity of the structural frame segments associated with the building units in each set of levels increases towards the base according to the height of the building. It is desirable that the inter-column area between adjacent units remains constant throughout the height of the building, so that the maximum column width is fixed. Thus, to accommodate increased loads nearer the bottom of the building, the columns 120, 122, and 124 are deeper (longitudinally) at their bottom than at the top. In this configuration, the first set of levels 112 have pillars of a first larger size, and the second set of levels (e.g., 114) have pillars of a second smaller size. This configuration continues in buildings. This progressive manner of increasing the column size downwards in the building (preferably in a ganged/stepped fashion) can be seen in table 1. This allows all the units to maintain a constant width regardless of the height of the building.

Fig. 10 is a perspective view of building 130, building 130 having 20 levels, and for simplicity five groups 132, 134, 136, 138 and 140 of four levels are shown, along with a central core 142. As seen in fig. 11A, the level 132 is made up of a first row of three building units 132A, 132B and 132C and a second row of three building units 132D, 132E and 132F. The level 132 includes two more building units 132G and 132H oriented at 90 ° relative to the other building units, as shown in fig. 11A. Fig. 11B, 11C, 11D and 11E show similar configurations of the building units therein. Since the order of installation depends on the parameters at the site and the design of the building, the order of installation of the individual building unit assemblies in the building is not set.

Fig. 12 is a more detailed schematic diagram of the level 132 of the building 130. It can be seen that the structural frame segments of the building unit assemblies 132A, 132B, 132C and the building unit assemblies 132D, 132E and 132F are interconnected with one another in a similar manner to that shown in figure 3. Includes end structural frame segments 150 and 152, the end structural frame segments 150 and 152 interfitting with complementary structural frame segments on the building unit assemblies 132G and 132H adjacent the building unit assemblies 132A, 132C, 132D and 132F. In the case of building unit assemblies 132B and 132E, the end structural frame segments 150 and 152 are bolted directly to mounting plates 154, 156, 158 and 160, the mounting plates 154, 156, 158 and 160 being cast into the core wall 142 or attached to the core wall 142 as shown.

Fig. 12 also diagrammatically shows the use of facade elements to provide a facade for building 130. In particular, an end facade member 162 is connected to each of the building unit assemblies 132A-132F. The side facade elements 164 are connected to the outsides of the building unit assemblies 132A, 132C, 132D and 132F. The side facade elements 164 are connected to the structural frame segments 16, 18, 20 and 22 of the building unit assemblies as shown. End facade elements (not shown) are connected to the ends of the building unit assemblies 132G and 132H. The side facade members 166 are connected to the sides of the building unit assemblies 132G and 132H via structural frame segments 168 as shown. The end facade elements 162 may carry loads and be integrated into the building unit assembly. Depending on the structural requirements of the building, steel and/or reinforced concrete may be used as both features and support structures. The facade elements may be solid or hollow to allow for spot joining or bulk concrete filling of the concrete elements. This provides a large and strong shear wall of facade elements. Balconies, railings and screens can be added to the facade as required. Facade elements may include non-structural cladding such as various metal panels, wood, glazed tiles, glass, and the like.

Fig. 13A is a schematic diagram of the floor arrangement of an apartment building 69, with ten apartments in each level. The building has a distributed core configuration somewhat similar to that shown in figure 8 and includes two stairwells 71 and 73 and two elevator wells 75 and 77. As shown in fig. 13B and 13C, each of the individual apartments is formed by two adjacent building units 72.1&72.2, 72.1&72.2 being arranged to provide the necessary space for the apartment. In this configuration, stairwells 71 and 73 are built into the building unit.

Fig. 13D and 13E show alternative apartment layouts using three building units and two building units respectively.

Fig. 14A-14B show two levels of a hotel building 79, the hotel building 79 having fourteen rooms in a lower level 81 (fig. 14A) and twelve rooms in a higher level 83 (fig. 14B). In this general arrangement, the elevator shaft 91 constitutes a side wall similar to the side wall 67 in fig. 7C, while the stairwells 87 and 89 are internal, similar to the arrangement in fig. 8. Basically, in this configuration, a single building unit 93 is used for each room in the hotel building, as shown in fig. 14C. In this construction, the elevator shaft and stairwell are constructed separately, rather than as part of a building unit. This helps support and stabilize the building.

Fig. 15A and 15B show a hybrid-use building 85 having both office space in a lower level of the building and residences in a higher level. Fig. 15A shows a typical floor layout of a dwelling using various building units. Building units of similar or different shapes may be used in lower levels and as commercial office space.

As mentioned above, the building units 2 may be arranged partly or substantially completely according to the requirements of the finished building. A detailed description of the techniques for configuring individual building units to achieve a particular floor layout is not required, as similar techniques have been used in low-rise structures, as has been described in some of the prior art documents referred to above.

Other portions of the structure and/or arrangement of the building may be implemented using or similar to known techniques. For example, the footing of any building assembled in this manner has footings constructed in a conventional manner to accommodate site conditions and the height of the building. However, the size and capacity of the footing can be reduced, and therefore, lower costs than conventionally constructed concrete buildings due to the reduced weight of buildings constructed in accordance with the present invention.

In the case of a need for a parking lot, the parking lot may be constructed in a conventional manner from concrete, as this type of construction is most suitable. The transfer levels may be formed in the top level of the parking lot due to the need to transfer loads from the units to the parking lot structure. In this way, the most economical and efficient layout of the structural elements can be obtained.

The roof of the unit can be made as a separate frame section and lifted into place on the uppermost unit and connected in the same way as the connections between the units. The roof is formed with short stakes that align with the underlying structural frame segments, steel side beams and steel purlins. Low walls are formed around the perimeter of each cell so that the entire roof is made up of cell-sized sections that are individually drained. After installation, metal caps are fitted over all of the low walls to waterproof the joints between the units. The roof covering may be a steel roof deck with conventional gutters and flashing or with plywood and a bituminous waterproof membrane. Additional manufactured products such as concrete pavers or wooden decks may be added to the formed roof deck. If desired, a planting platform and walkway may be added.

Drainage may be achieved by a downpipe from a gutter in a steel sheet roof or a downpipe connected to the roof outlet. The downspout is typically located on the outside of the building.

Drainage of the balcony can be achieved in the same way as membrane-made roofs by using downpipes connected to balcony drains. Balcony drains are typically aligned with the roof outlet so that a single downpipe connecting the roof outlet and balcony drains can be used on each round trip.

Auxiliary and assembly members may be included in each unit. And may be removed from the fixture and fitting and mounted to a central point for attachment after installation.

Installation of the main risers (pipes, tubes, drains, etc.) and cables (wires, telephone lines, data lines, etc.) can be carried out in the field in a conventional manner.

The planting device is built in much the same way as in a conventional building. The type of vegetation is determined by the building size, the type and availability of the accessories available or needed.

Figure 16 illustrates in more detail the structure of one embodiment of the building unit assembly 2 and the novel connecting assembly for interconnecting the various units. In a broad sense, the construction of such building unit assemblies follows the following procedure: a self-supporting unit is constructed and then more than one support post is attached to the exterior of the self-supporting unit.

In the illustrated arrangement, the side walls 6 are formed from profiled steel sheet 179 similar to that used in shipping containers. Typically, the steel plate has a thickness of about 1.6mm, and a single steel plate is used for the entire wall, which may have a height of about 2700mm and a length between 10m and 20 m. The side wall 6 includes an upper rail 180, the upper rail 180 being welded to the top edge of the profiled wall panel 179. Typically, the rungs 180 are 60 x 60mm and have a wall thickness of about 3 mm. Side wall 6 also includes a lower ledge 182 having a generally C-shaped cross-section, lower ledge 182 having a lower flange 183 and a wider upper flange 185 welded to the bottom edge of plate 179. The central belly portion of the lower rail 182 is typically 160mm deep and the material has a thickness of about 4.5 mm.

The floor 8 may be constructed from a plurality of steel beams 184, the steel beams 184 extending transversely across the building between the side walls 6 and being positioned at 400mm intervals. The ends of the stringers are welded or bolted to the central web of the lower crosspiece 182 of the side wall 6 as shown. The floor further comprises plywood flooring 186 mounted to the stringers 184 by screws or the like.

Roof 10 is constructed of profiled steel sheets 186 which may be the same as those used in side walls 6. The roof further includes roof rails 188, which in the illustrated configuration are L-section channels, approximately 55 x 55mm, with a 6mm wall thickness. Roof rail 188 may be welded or bolted to upper rail 180 of side wall 6.

The other side wall 4 of the building unit 2 is of similar construction and need not be described.

The components of the side walls 4 and 6, floor 8 and roof 10 define a box-like structure of the building unit which is capable of supporting its own weight and the dynamic loads applied to it in use. In the illustrated configuration, the interior side walls are lined with double-layer fire-rated gypsum boards 190 and 192 connected to the interior side of the panel 179 by upper and lower battens 194 and 196. Similarly, the roof is lined with two plasterboards 198 and 200 connected to the inner faces of the panels 186 by ceiling battens 202. The double layer of gypsum board, together with the air gap space between the gypsum board and the profiled sheet 179 and panel 186, enhances the fire rating of the building units and the sound insulating effect between the building units.

Figure 16 also shows the column element 22 and the lower and upper mounting blocks 24, 26. In the arrangement shown in the drawings, the column element 22 is formed from a square section steel beam of approximately 100 x 100mm and having a wall thickness of approximately 9 mm. The upper end 20 of the column element 22 is welded directly to the upper rail 180 of the side wall 6. The top of the column element 22 is welded to the upper mounting block 26 and the bottom of the column element 22 is welded to the lower mounting block 24. In the illustrated arrangement, the lower mounting block 24 is slightly wider than the upper mounting block 26, and the inner edges of the lower mounting block 24 extend into and are welded to the channels forming the lower crosspiece 182 of the side wall 6. This completes the connection of the column element 22 and the mounting blocks 24 and 26 to the side wall 6. The other column elements 16, 18 and 20 of the building unit assembly are connected in a similar manner and need not be described.

Advantageously, a stress relief step is performed prior to attaching the structural frame segment 22. For example, when building a unit with a clamp or by clamping, the stress relief step typically includes releasing the clamping force applied by the clamp or jaws. For units having a welded metal construction, the stress relief step may include allowing any thermal stresses in the metal to dissipate, for example, by cooling. In this manner, the box-like unit or monocoque construction relaxes to its natural shape, possibly including deforming or deviating from its design shape. The column element 22 may then be attached as described herein. In this way, accurate placement (relative to the original design) of the column element can be achieved, as the column element does not depend on the accuracy of the shape of the unit monocoque construction. Typically, the mounting means used to attach the column element 22 to the unit are of sufficient tolerance to absorb deviations of the unit.

As mentioned above, the separation of the building unit construction from the construction of the structural frame segments of the building unit assembly improves the ease of manufacture as only those parts of the building unit assembly which require precise positioning are made to precise tolerances. The remainder of the building unit housing, for example, may be manufactured to other tolerance levels.

Due to the precise placement of the structural frame segments, the structural frame segments (or points on the structural frame segments) may be used as a reference for arranging the interior of the unit and assembling any facade components. That is, rather than using the walls of the building unit to guide the placement or attachment of the facade, as the walls may not be straight or perpendicular, but rather take the structural frame segment 22 as a reference. To achieve this, the measurements form a reference point (e.g., a point on the inner sidewall of the post and transfer to the interior of the self-supporting unit). Measurements of the internal arrangement can then be made from this shifted reference point. It will be appreciated that a plurality of such reference points may be required.

A first mounting means in the form of a lower mounting block 24 is illustrated in more detail in figures 17 to 20. The mounting block typically takes the form of a hollow cuboid having an open end, as best shown in fig. 17. More particularly, the block has a top wall 210, a bottom wall 212, and side walls 214 and 216. The block has an inner open side 218 and an outer open side 220. The top and bottom walls 210 and 212 include aligned holes 222 and 224 that are offset toward the outer open side 220, as best shown in fig. 18. The block 24 typically has a width of about 165mm, a height of about 160mm and a length of about 160 mm. The block 24 is preferably made of construction rebar and the side walls have a thickness of about 16mm, while the top wall 210 and the bottom wall 212 have a thickness of 20 mm.

Fig. 21 to 24 diagrammatically show the structure of the upper mounting block 26. The block 26 is also a generally hollow cuboid. The block 26 has a top wall 230, a bottom wall 232, and side walls 234 and 236. The block 26 also has open side walls 238 and 240. Sidewalls 234 and 236 include alignment holes 242 and 244 located at approximately the center of the sidewalls. The bottom wall 232 includes an opening 246 approximately at its center. The top wall 230 includes a larger tapered opening 248. The opening 248 is generally rectangular, but with curved corners. The taper is about 10 deg., and the wider portion of the opening 248 is located on the upper surface of the top wall 230 as shown. In the illustrated configuration, the upper mounting block 26 has a height of about 195mm, a width of about 120mm, and a depth of 160 mm. The block is made of constructional grade steel and the side walls 234 and 236 have a wall thickness of about 16mm, the bottom wall 232 has a wall thickness of 20mm and the top wall 230 has a wall thickness of 40 mm.

Fig. 25, 26 and 27 are exploded views showing how a pair of lower adjacent building unit assemblies 2A and 2B are connected to a pair of upper adjacent building unit assemblies 2C and 2D. As can be seen in fig. 25, the lower mounting block 24A of the upper unit 2C is mounted directly on the upper mounting block 26A of the lower building unit assembly 2A. More particularly, the bottom wall 212C of the upper building unit assembly 2C bears directly on the top wall 230A of the lower unit. It can also be seen that the column elements 22A and 22C are aligned with each other. Similar configurations exist at other points where the mounting blocks of the two building unit assemblies 2A and 2C are joined to each other. In this way the entire vertical load of the upper building unit assembly 2C is transmitted via the mounting blocks to the lower building unit assembly 2A and then into the column elements.

Fig. 26 is a view similar to fig. 25, except showing the positions of some of the components of the building unit assemblies 2B and 2C beside the building unit assemblies 2A and 2C, respectively. More particularly, fig. 26 shows the location of the structural frame segments 16B and 16D and the location of the mounting blocks 26B and 24D.

In the illustrated configuration, there are three types of connections, which are referred to for convenience as type 1 connections 250, type 2 connections 252, and type 3 connections 254. Generally speaking, type 1 connections 250 as shown in figure 28 are used to connect together the upper mounting blocks of the lowermost building unit assembly and the lower mounting blocks of the uppermost unit. In the illustrated configuration, the type 1 connection 250 is used to connect the upper mounting block 26A to the lower mounting block 24C, as shown. Similarly, type 1 connection 250 is used to connect upper mounting block 26C to the immediately vertically adjacent mounting block.

A type 2 connection 252 as shown in fig. 29 is used to connect adjacent upper mounting blocks 26 together. In the illustrated configuration, a type 2 connection 252 is used to connect the upper mounting blocks 26A and 26B together. Similarly, type 2 connections 252 are used to connect the upper mounting blocks 26C and 26D together.

The type 3 connection 254 as shown in fig. 30 is used to vertically connect adjacent units that cannot use the type 1 connection 250 because they cannot enter the interior of the lower mounting block 24, as will be explained below. The type 3 connection 254 comprises an elongate connecting rod extending from the upper mounting block 26 of one building unit assembly to the upper mounting block 26 of an immediately vertically adjacent unit.

Fig. 28 illustrates the type 1 connection 250 in more detail. Type 1 connection 250 includes a bolt 260 having a rectangular head 262, the rectangular head 262 having tapered sides (tapered sides) as shown. The connection includes tapered spacers 264, the tapered spacers 264 being generally rectangular parallelepiped in shape but having tapered sides to complement the shape of the opening 248 in the top wall 230 of the upper mounting block 26. Tapered spacer 264 includes a central bore 265 to allow the shaft of bolt 260 to pass therethrough. The connection includes a washer 266 and a nut 268. As seen in fig. 25, the lower and upper mounting blocks 24 and 26 have respective open side walls 218A and 238C, which open side walls 218A and 238C are exposed to allow access to the interior of the mounting blocks by construction workers. The tapered spacer 264 is initially located in the opening 248 before the upper building unit assembly 2C is placed on the lower building unit assembly 2A. The building unit assembly 2C can then be lowered into position and the shaft of the bolt 260 can be guided through the bore 265 of the spacer 264 and then through the opening 246 of the bottom wall 232 of the lower mounting block 24. The construction worker may then place the washer 266 and nut 268 on the shaft of the bolt 260 and tighten the nut, access being achieved through the open sidewall 218 of the lower mounting block 24. The complementary tapers of the spacer 264 and the opening 248 ensure that the axes of the bolts are correctly centred and thus that there is correct alignment between the upper and lower building unit assemblies. Fig. 31 diagrammatically illustrates the position of the head 262 of the bolt of the type 1 connection 250 prior to lowering the upper building unit assembly into position. It can be seen that the tapered sides of the head 262 are generally aligned with the tapered sides of the tapered spacer 264. After lowering the uppermost unit into position, the head 262 may then be rotated 90 ° so that the head 262 occupies the position shown in fig. 28 in which the head 262 can bear against the underside of the top wall 230 of the mounting block 26.

Fig. 29 schematically illustrates a type 2 connection 252 between adjacent upper mounting blocks 26A and 26B. The connection includes a bolt 270, a nut 272, and a washer 274.

It can be seen that sidewalls 236A and 234B are adjacent to each other and their respective openings 244A and 242B are also aligned. The shaft of the bolt 270 can pass through the aligned openings so that the operator can then install the washer 274 and tighten the nut 272. Access to the interior of the mounting blocks 26A and 26B is provided via the mounting block's open side walls 238A and 238B.

Fig. 30 diagrammatically illustrates a type 3 connection 254 for connecting the building unit assemblies 2B and 2D together vertically. The type 3 connection 254 includes an elongated rod 271 and a head 273. The head 273 is a generally rectangular parallelepiped with tapered sides and is similar in shape to the head 262. The connection includes a tapered spacer 275, the tapered spacer 275 having a shape that is generally complementary to the tapered opening 248B of the upper mounting block 26B. The tapered spacer 275 includes a central bore 276 to allow the stem 271 to pass therethrough. The upper end of the stem 271 is threaded so that it can receive a washer 278 and nut 280 thereon. In the illustrated configuration, the head 271 engages the underside of the top wall 230B of the mounting block 26B. The shaft of the rod 271 passes through the structural frame segment 16D through the openings 222D and 224D of the lower mounting block 24D so that the free end of the shaft is located within the upper mounting block 26D, as shown. FIG. 32 shows the position of the head 271 of a type 3 connection 254 when the head 271 is lowered into position. Upon lowering the uppermost building unit assembly 20 into position, the head portion 273 can be rotated 90 ° so that the head portion 273 again engages the underside of the top wall of the mounting block 26B. The aligned tapered faces of the bolt head and tapered spacer help in the alignment of the units during installation and tightening. The construction worker may then tighten the nuts 280 to securely interconnect the building unit assemblies 2B and 2D.

Typically, the building unit assembly can be lifted using a crane having hooks or other fastening devices that can be connected to the four upper mounting blocks 26 of the building unit assembly. The type of connection may be similar to that used for lifting and transporting shipping containers.

Referring now to fig. 27, fig. 27 shows a side view of the connection between a pair of lower adjacent building unit assemblies 1A, 2B and a pair of upper adjacent building unit assemblies 2C and 2D. This configuration includes a total of three connections (type 1, type 2 and type 3) connecting the units 2A, 2B, 2C, 2D and is assembled into one assembly in the following way: the building unit assembly 2C is mounted on the building unit assembly 2A with the vertical connections being made by type 1 connections 250. This is followed by lowering the building unit assembly 2B into position adjacent the building unit assembly 2A, the horizontal connection being completed using the type 2 connection 252. Once the building unit assembly 2B has been lowered into position, the interior of the mounting blocks 26A and 26B is no longer accessible and therefore the manufacturer cannot place the components of the type 1 connection therein. Thus, a type 3 connection is required.

Fig. 33 is a diagrammatic side view showing a four-level building 280 including a plurality of building unit assemblies of the type previously described. The cells are interconnected using type 1 connections 250, type 2 connections 252 and type 3 connections 254 as shown. The preferred sequence of assembly of the various building units in the building 280 is shown in the figures as large and thick numbers. The exact order of unit installation is determined by the site and lifting conditions, but the construction is performed in a substantially diagonal direction. In this figure, the building includes a foundation 282, the foundation 282 including a mounting plate to which the type 1 connection 250 is coupled to securely anchor the building to the foundation.

Figures 34 to 51 illustrate an alternative set of mounting means. The alternative mounting means may be used in embodiments of the invention. In this regard, rather than mounting blocks, each column is provided with a connecting plate for securing adjacent building unit assemblies together as will be described.

Details of another embodiment of the lower and upper connector plates 24, 26 will now be described with reference to fig. 34-51. In the foregoing description, the lower web is identified by the reference numeral 24 by category. However, in a preferred form of the invention, there are two types of lower connecting plates. The first lower connecting plate 206 is schematically illustrated in fig. 34, 35 and 36. The first lower connecting plate 206 essentially comprises a rectangular steel plate 210, the rectangular steel plate 210 having a nominal thickness of about 25mm, but the thickness may vary as desired. In the illustrated arrangement, the plates are 290mm in length and 145mm in width, and these dimensions may vary as desired. The tapered protrusion 211 is located on the bottom side of the plate 210. The protrusion 211 may be fixed to the plate 210 by welding or the like. In the illustrated configuration, the protrusion 211 is generally cuboid in shape and has a depth of 20mm, a length of about 91mm and a width of about 53 mm. The taper corresponds to about 2.5mm on each side or between about 5 ° and 10 °. The corners of the protrusions are preferably rounded and have a radius of curvature in the range from 5mm to 15 mm. Plate 210 includes a first bore 212, a second bore 213, and a third bore 214. The diameter of the bore 212 is larger than the diameters of the other bores and the bore 212 is located on the central longitudinal axis. Preferably, the bore 212 is 32mm in diameter. Bores 213 and 214 are aligned generally symmetrically between the protrusion 211 and one end of the plate. The bores 213 and 214 are preferably 26mm in diameter.

A second type of lower connecting plate 215 is shown in fig. 36 and 37. The second type of connecting plate 215 comprises a square plate 216, the square plate 216 having the same thickness as the plate 210, and the edge of the square plate 216 being half the longitudinal length of the plate 210.

Thus, in the illustrated arrangement, the sides are 145mm in length. The bottom side of the plate 216 comprises symmetrically arranged protrusions 217 having the same shape as the protrusions 211. The end view shown in fig. 36 of the first type of lower connecting plate 206 is the same as the end view of the second type of lower connecting plate 215. The plate 216 does not include any drilled holes.

In the foregoing description, the upper connection plate is denoted by the reference numeral 26 by category. There are actually two forms of upper connecting plates. As will be explained below, similar elements are used to denote different types of upper connecting plates, but these similar components are oriented differently in the building unit assembly.

Fig. 38 to 41 diagrammatically illustrate a preferred shape of the upper connecting plate 218. The connecting plate 218 may be formed from an initially rectangular sheet of steel 219, the dimensions of the sheet 219 being substantially the same as the sheet 210 shown in figure 16, except that the thickness of the sheet 219 is preferably 40 mm. The upper web 218 has a corner removed therefrom to define a rectangular tab portion 220. The angle removed is preferably 75mm x 75 mm. Plate 219 includes a centrally located tapered recess 221. tapered recess 221 is complementary in size and taper to protrusions 211 and 217 of lower connector plates 206 and 215. Plate 219 includes a first bore 222 and a second bore 223, wherein the first bore 222 is located generally along the longitudinal axis of plate 219 between one end of the plate and the groove 221, and the second bore 223 is located generally in the center of the tab portion 220.

The bores 222 and 223 preferably have diameters of 34mm and 28mm respectively. As will be described in more detail below, the upper connecting plates 218 may be mounted on the building unit assemblies 2 in different orientations so that the upper and lower connecting plates may be used to interconnect laterally adjacent and vertically adjacent building unit assemblies 2. All the connecting plates are made of 350 grade or larger steel.

Fig. 42 and 43 schematically illustrate how mounting means in the form of connecting plates 206, 215 and 218 are connected to the column elements 18 and 20 to form the structural frame segments 4218 and 4220. Figure 42 shows a column element 18 in which configuration the column element 18 is a square section hollow steel column having a length of 125mm and a width of 125mm, a wall thickness of about 4mm to 10mm and an overall length of 3050mm including the webs. A top connection plate 206 is welded to the upper end of the column element 18 so that the centre of the groove 221 is aligned with the longitudinal axis of the column element 18. A lower connecting plate 215 is welded to the lower end of the column element 18 so that the centre of its projection 217 is aligned with the longitudinal axis of the column element 18. This ensures that the groove 221 is accurately aligned with the protrusion 217.

Fig. 43 schematically illustrates a structural frame segment 4220. The structural frame section is formed by welding a top connection plate 218 to the upper end of the column element 20 and a lower connection plate 206 to the lower end of the column element 20. Likewise, the centers of the groove 221 and the protrusion 211 are aligned with the longitudinal axis of the column element 20. The column element 20 is formed from the same segments as those used to form the element 18 and is of the same size.

In an alternative embodiment, the structural frame segment may have the mounting means and column elements formed integrally. In this case the mounting means will be the part of the column element that in use engages the adjacent column element and the part that is used to fasten the column element together with the adjacent column element.

Fig. 44 shows the position of the structural frame segments of a pair of laterally adjacent building unit assemblies 2A and 2B. For the structural frame segment 18A of the building unit assembly 2A, the orientation of the upper connecting plate 218 is selected such that the tabs 220 are adjacent the side walls 4 and point away from the structural frame segment 16A. On the same side, the structural frame segment 16A has the tabs 220 oriented in the same manner. The structural frame segment 16A is identical to the structural frame segment 18A, so the lower connecting plate 215 will be located at the lower end of these structural frame segments.

On the other side wall 6A, the structural frame segment 20A is positioned such that its tab portion 220 is oppositely oriented with respect to the tab adjacent to the side wall 4A. The structural frame segment 22A has the same construction as the structural frame segment 20A. Thus, it should be understood that both structural frame segments 20A and 22A have a first lower connecting plate 206 at their lower ends.

The building unit assembly 2B and the building unit assembly 2A have an identical construction and therefore the column elements and the upper and lower connecting plates of the building unit assembly 2B are identical to those in the building unit assembly 2A.

Fig. 45 shows the building unit assemblies 2A and 2B stacked together laterally such that the tab portions 220 of the lower connecting plates 206 form interengagement as shown.

The column elements 16, 18, 20 and 22 may be welded to the side walls and/or framing of the building unit assemblies 2A and 2B at selected locations to enable the column elements to be connected together laterally as well as vertically as shown in fig. 45, as will be described in more detail below.

Figure 46 schematically illustrates an isometric view of a plurality of building unit assemblies assembled together. The front-most unit 2B is visible as having a structural frame segment 18B connected to the side wall 4B of the building unit assembly 2B. The length of the structural frame segment 18B is selected so that the top of the upper connecting plate 218B is located about 100mm above the plane of the roof 10B.

An elongated connecting rod 207B having a threaded end extends through the bore 222B and the lower end of the elongated connecting rod 207B engages a threaded coupling member (not shown in fig. 41) located adjacent the bottom of the structural frame segment 18B, as will be explained in more detail below. A nut 209B is fastened to the threaded end of the connecting rod 207B. As shown in fig. 47, the laterally adjacent building unit assemblies 2A may then be positioned such that the side structural frame segments 20A of the building unit assemblies 2A are adjacent to the structural frame segments 18B, as shown. In this position, tab portions 220A and 220B are arranged side-by-side. At the other end of the building unit assemblies 2A and 2B, structural frame segments 22A and 16B are similarly configured.

After the building unit assemblies 2A and 2B are aligned, a third building unit assembly 2C may be lowered onto the top of the building unit assembly 2B with the structural frame segment 20C vertically aligned with the structural frame segment 20A as shown in fig. 48. The coupling part 233B may be coupled to a protruding end of the coupling rod 207B as shown.

The coupling member 233B is essentially an elongated nut that is capable of receiving the threaded lower end of the adjacent upper elongated connecting rod 207D (as shown in fig. 50). The building unit assembly 2C is lowered so that the protrusion 211C of the post 20C enters the groove 221A of the post 20A and this is easy to automatically correctly align the building unit assemblies 2C and 2A due to their complementary conical shape. When the building unit assembly 2C is lowered, all the protrusions 211 and 217 of the building unit assembly 2C will enter into the corresponding grooves 221 of the building unit assembly 2B. Bolts 224, 225 and 226 are then introduced through the aligned bores in plates 206C and 218A, 218B. More particularly, bolt 224 extends through bores 212C and 222A; bolt 225 extends through bores 214C and 223A, and bolt 226 extends through bores 213C and 223B. Nuts 227, 228, and 229 may be tightened onto the respective bolts to securely attach the plates together, as shown in fig. 49.

After all the nuts have been tightened, the fourth building unit assembly 2D may then be lowered into position over the building unit assembly 2A. For ease of clarity in illustration in fig. 49, only the structural frame segments 20D of the building unit assembly 2D are shown. The building unit assembly 2D is lowered to a position such that its projection 217D enters the groove 221B of the building unit assembly 2B. The four tapered protrusions of the building unit assembly 2D will assist in the correct alignment of the building unit assembly 2D over the building unit assembly 2A.

Fig. 50 shows the final position of the individual plates. It can be seen that plate 215D bears against plate 218B and is held in place by means of elongate connecting rod 207D, as shown. The elongated connecting rod 207 is preferably made of a 30mm diameter steel rod and is threaded at its ends or along its entire length.

It will be appreciated that the nuts 227, 228 and 229 may be tightened before the fourth building unit assembly 2D is lowered into position. Once this occurs, access to the connector plates is not available and the use of the elongate connector plates 207D allows the final connection to be made by the assembler working from the roof of the building unit assemblies 2C and 2D above. The standard procedure for installing the elongated connector rod 207D is as follows: prior to positioning the fourth building unit assembly 2D, the lower end of the elongated connecting rod 207D is screwed into the coupling member 233B. The building unit assembly 2D is then positioned over the building unit assembly 2A, and the upper end of the rod 207D is aligned with the bore 222 of the roof (not shown) of the structural frame segment 18D. The building unit assembly 2D may then be lowered so that the upper end of the rod 207D extends through the bore. The sequence is similar for all structural frame segments of the building unit assembly 2D.

It will be further appreciated that the illustrated arrangement provides very robust vertical and lateral connections for the connector plates, and thus very robust connections for the structural frame segments. This gives rigidity and stability to the building.

It will be appreciated that the location of the connecting plate may be other, i.e. the protrusions may be located on the upper plate. Also, a complementary plate may be used for the lower plate, rather than the upper plate being complementary in the illustrated arrangement.

Fig. 52 to 67 illustrate yet another embodiment of the mounting device and method of use of the mounting device in connecting building unit assemblies to one another. This example represents a hybrid between the previous embodiments using both a connection plate and a mounting block.

An exemplary lower connecting plate 310 is illustrated in more detail in fig. 52, 53 and 54. It can be seen that the plate 310 comprises a rectangular base 312, the rectangular base 312 having side walls of about 125mm in length and 25mm in thickness, the upper edge of the base being chamfered. The plate 310 includes a locating protrusion 314, the locating protrusion 314 being cast or fabricated from steel and welded to the underside of the base 312. The protrusion 314 is generally rectangular parallelepiped, but has downwardly tapered side and end walls, as shown. The lower web 310 includes a central bore 316 and a protrusion 314 through the base 312. Typically, the bore 316 is about 332mm in diameter.

In the building unit assembly 300, the upper ends of the structural frame segments 16, 18, 20 and 22 are provided with upper connecting plates 318 or upper mounting blocks 320 depending on the unit to be configured. Basically, the building mounting block 320 is used in situations where access is problematic and an elongated connector is required, similar to the type 3 connection 254 of the previous embodiment, as will be described in more detail below.

Fig. 55-57 illustrate the upper connecting plate 318 in more detail. As can be seen, the upper web 318 is in the form of a rectangular plate and is the same size as the base 312 of the lower web. The upper web 318 includes an oblong opening 324, the oblong opening 324 having tapered sidewalls that are complementary to the tapered sidewalls of the protrusion 314 so that the protrusion 314 can fit properly within the oblong opening 324.

Fig. 58-60 illustrate the upper mounting block 320 in more detail. The upper mounting block 320 is welded to the upper end of the column element as shown below and is used where an elongate rod is required due to the lack of access ports, as is the case with the type 3 connection 254. The upper mounting block 320 has substantially the same construction as the upper mounting block 26 shown in fig. 21 to 24, and the same reference numerals are used to designate the same or corresponding parts as in that embodiment. In this case, the opening 248 has a complementary shape to the projection 314 so that the building unit assemblies 300 can be properly fitted together when stacked on top of each other.

Fig. 61-65 illustrate bolts 330 that can be used in conjunction with the lower and upper connecting plates 310, 320 for connecting the lower and upper connecting plates 310, 320 together. Bolt 330 has a head 332 and a shaft 334. The head 332 is generally rectangular parallelepiped in shape but has side and end walls that taper by about 10 degrees. The shaft 334 is made in two lengths, the shorter length being about 120mm (similar to the type 1 connector) and the longer length being such that the shaft 334 can extend through the entire height of the building unit 300 (similar to the type 3 connector). Typically, the longer form has a length of about 3025 mm. In either case, the upper end 336 of the shaft is threaded such that the upper end 336 can receive a nut 338. Protruding beyond the threads is a square protrusion 340, best seen in fig. 63 and 65.

Fig. 66 and 66A illustrate how the upper connecting plate 310C is welded to the respective support columns 22A and 22C, respectively, to mate with each other to connect the units 310C and 310A in alignment with each other using the features described above. Fig. 67 illustrates a similar example, but using an upper mounting block 320 and a lower connecting plate 310C.

Fig. 67 shows how four adjacent building unit assemblies 300A, 300B, 300C and 300D are interconnected using bolts 330. This configuration is similar to that shown in fig. 27 of the previous embodiment and therefore need not be described in detail. However, it can be seen that the lower end of the structural frame segment 22 includes an access opening 360 to enable access to the nut 338 for connecting the upper and lower connecting plates. Additionally, where column elements are provided with upper connecting plates 318, access openings 362 are provided to enable horizontally disposed bolts 364 to pass therethrough to interconnect the structural frame segments as shown. In the illustrated arrangement, the head of the bolt 364 is located outside of the hollow interior of the column element 22A. This enables the head of the bolt 364 to be retained to facilitate tightening of the nut 365 located within the upper mounting block 320D. In this configuration, the bolt includes a flange 367 and a washer is located on the shaft of bolt 364 between upper mounting blocks 320B, which configuration is such that tightening nut 365 effectively clamps the upper end of structural frame segment 22A, washer 369 and upper mounting blocks 320B together. FIG. 68 shows a similar diagram to FIG. 16, but showing a different cell configuration. In the illustrated arrangement, the side walls 6 are formed from profiled steel sheets 179 similar to the materials used in shipping containers. Typically, the steel plate has a thickness of about 1.6mm and a single steel plate is used for the entire wall, which may have a height of about 2700mm and a length between 10m and 20 m. The side wall 6 includes an upper rail 180, said upper rail 180 being welded to the top edge of the profiled wall panel 179. Typically, the rungs 180 are 60mm by 60mm and have a wall thickness of about 3 mm. Side wall 6 also includes a lower ledge 182, lower ledge 182 having a generally C-shaped cross-section and having a lower flange 183 and a wider upper flange 185 welded to the lower edge of plate 179. The central belly portion of the lower rail 182 is typically 160mm deep and the material has a thickness of about 4.5 mm.

The floor 8 may be constructed from stringers running across the building units. Preferably, however, the floor is made of profiled steel sheet panels 184 of a material similar to that of the side walls, except that the depth of the profile is approximately 200 mm. The panels extend laterally, the arrangement providing sufficient rigidity and strength to the building unit. The ends of the floor panels 184 are welded to the bottom rail 182 on either side of the building unit. Roof 10 is preferably made of roof panels 186, an example of which is shown in fig. 69, 70 and 71. Typically, 4 to 8 panels are welded together to form the entire roof of the building unit. Each panel 186 is formed of longitudinal and transverse stiffeners as shown diagrammatically in fig. 70. The panels are preferably made from steel sheet having a thickness of about 2mm, a width of 1045mm and a length of 2356 mm. The flooring further includes plywood or other flooring material 186 located over the top of the profiled floor panel 184. The other side wall 4 of the building unit 2 is of similar construction and need not be described.

The components of the side walls 4 and 6, floor 8 and roof 10 define a box-like structure capable of supporting its own weight and the dynamic loads applied to it in use. In the illustrated arrangement, the interior side walls are lined with a layer of fire-resistant gypsum board 190, the fire-resistant gypsum board 190 being adjacent to the insulating panel 192. The roof is lined with two plasterboards 198 and 200 connected to the inner face of the panel 186 by ceiling battens 202. The double layer of gypsum board, together with the air gap space between the gypsum board and the profiled sheet 179 and panel 186, enhances the fire rating of the building units and the sound insulating effect between the building units.

In the configuration illustrated in fig. 76, the column member 20 is welded directly to the upper rail 180. At the lower end, two connection plates 187 (one of which is shown in fig. 68) are used to connect the lower end of the column element 20 to the lower crosspiece 182, preferably by welding. Other structural frame segments of the building unit assembly are connected in a similar manner.

Fig. 72 to 77 schematically illustrate the improved building unit assembly 300 and like reference numerals are used to indicate like or corresponding parts to those in the building unit assembly 2. The primary difference between the building unit assembly 300 and the building unit assembly 2 is the construction of the floor 8 and the connecting plates 24 and 26. In the arrangement of fig. 72 to 74, the floor stringers 184 are replaced by floor panels 304, the floor panels 304 being of generally corrugated steel sheet construction, as shown in fig. 76. The panels 304 are similar to those used in side walls and roofs, except that the panels 304 are relatively deep, typically about 200mm (measured in the vertical direction). The pitch of the corrugations (pitch) is typically about 650 mm. Multiple panels 304 may be welded together as a single piece to form the entire structure of the floor of unit 300. Typically, the wall thickness of the panel 304 is 1.6 mm. As previously described, the structural frame segments 16, 18, 20 and 22 are attached to the sidewalls 4 and 6. As explained in more detail above, the connecting plates 24 and 26 of the building unit assembly 2 are the same as previously described.

In the illustrated configuration, the building unit assembly 300 includes two lateral support panels 306 and 308 arranged to provide additional rigidity. Panels 306 and 308 are welded inwardly to sidewalls 4 and 6 and roof 10 adjacent to structural frame segments 16 and 22 and structural frame segments 18 and 20, respectively.

Fig. 74 shows the positions of the structural frame segments 20 and 22 where the building unit assembly 300 is used in a cantilevered configuration. As shown in this figure, the center span, i.e., the center span between the structural frame segments 20 and 22, can be up to about 16mm, 16 meters, and each end can be suspended up to 6mm, 6 meters.

Fig. 75 shows six building unit assemblies 300B, 300C, 300D, 300E, 300F and 300G stacked as previously described. The gaps or inter-column areas between adjacent building units 300 are selected to accommodate structural frame segments of different widths. As with the previous embodiments, the gap may remain the same throughout the height of the building.

As best seen in fig. 77, the lower ends of the column elements 16, 18, 20 and 22 are provided with lower connection plates 310, the lower connection plates 310 being welded to the lower ends of the column elements and replacing the lower mounting blocks 24 of the earlier embodiment.

Fig. 77 is a schematic sectional view showing a more detailed part of the building unit assembly 300. Fig. 44 is a view similar to fig. 68, and fig. 44 shows different details of the construction of the building unit assembly 2. It can be seen that in this configuration, the lower crosspiece 182 is formed of rolled steel and has upper and lower flanges that project in opposite directions. The lower flange 183 is welded to the underside of the floor panel 304 as shown. The upper flange 185 is welded to the lower edge of the profiled wall panel 179 as in the previous embodiment.

Fig. 78 shows a further modified building unit assembly 350 which combines the components of the building unit assemblies 2 and 300. More particularly, the floor 8 includes stringers 184 but the connection of the top and bottom of the structural frame segments is the same as in the building unit assembly 300. In this embodiment, the reinforcement beam 352 may be welded between the crosspiece 182 and the lower end of the structural frame segment, if desired.

Fig. 79 illustrates the construction of another alternative building unit which may be used in embodiments of the present invention. This embodiment differs from the previous embodiments substantially in that in this embodiment, for the construction of walls, floors and roofs, mainly flat sheet material is used, instead of the corrugated profiled sheet material used in the previous embodiments. In the embodiment of fig. 79, the walls, floor and roof are reinforced by placing stringers at intervals along the length of the section. In fig. 79, a partially exploded cross-sectional view of the building unit 400 can be seen. The building units include wall panels 402, roof panels 404 and floor panels 406.

Roof panel 404 has a corner section 408, and corner section 408 may be, for example, a 110mm by 110mm angled section having a thickness of 4 mm. The corner segments 408 are welded to a wall panel type material 410, which wall panel type material 410 may be a 1.6mm thick steel plate.

A series of stringers 411 extend across roof panel 404 to another angled section identical to section 408. The stringer 411 is welded on its end face to the angled section 408 and along its top edge to the sheet 410. Similar stringers 411 are spaced at intervals of, for example, 600mm along the roof panel. In a preferred embodiment, the stringers are C10019 gauge stringers.

The construction of the wall panel 402 is similar to that of the roof panel 404. On top of the wall panel 402 there is an angled section 412. Angled section 412 supports the roof panel and may have similar dimensions to angled section 408 on the roof panel. The second angled section 414 is located at the bottom of the roof panel 402. The angled section 414 supports the floor panel 406. In this example, the lower corner 414 has a dimension of 210mm by 110mm and a thickness of 3 mm. The surface of the wall panel is coated with a steel sheet, for example 2.4mm450MPa steel sheet. The steel plate is welded at its top to corner 412 and at its bottom to corner 414. The steel panel wall panel 416 is stiffened using C stringers 418 extending between the lower angled section 414 and the upper angled section 412. The C stringers are spaced at intervals along the length of the wall and welded to the wall. In the illustrated embodiment, the stringers 418 may be C7519 gauge stringers set at 600mm intervals along the wall.

Floor panel 406 has a similar construction to roof 404 and walls 402. The floor panel 406 has an angled section 420 at each end (only one end is shown in this figure) to which a lower floor panel composed of a steel plate panel 422 is welded. On top of the floor panel 422 there are welded C stringers that run between the angled sections 420 on either side of the floor. In this case, the floor stringer may be of a C20019 gauge set at 600mm intervals along the floor panel.

As with the previous embodiments, the roof, floor and wall panels are brought into engagement and welded together.

It should be understood that in the embodiments illustrated herein, the building unit structures are described as being welded together. However, one skilled in the art will readily appreciate that alternative fastening and attachment means may be employed. For example, instead of welding, rivets, bolts or other mechanical fastening systems may be used to join the components together. Gluing may also be suitable, depending on the configuration of the material used. Also, depending on the workability and materials used, different welding techniques may be used, such as MIG welding, TIG welding, spot welding or other options.

Fig. 80 shows another alternative wall configuration very similar to fig. 79. The only difference is that in the embodiment of fig. 80, the angled section at the lower end of the wall panel is inverted. Therefore, no further explanation of this embodiment is necessary, and the features corresponding to those in fig. 79 are denoted by the same reference numerals.

FIG. 81 illustrates a perspective view of an alternative connection plate that may be used with embodiments of the present invention. In general, the structural frame segments 800 shown in fig. 81 are substantially similar to those already described herein, and thus, only one end of the structural frame segment 800 is shown in this figure. In this regard, the structural frame segment 800 includes support posts 802 and connection plates 804. In this example, the connection plate 804 has a generally rectangular first end 806 and a tapered second end 808. Thus, in plan view, the connecting plate 804 is generally trapezoidal in shape, as best illustrated in fig. 82. As in the previous embodiment, the connection plate has: a central recess 810 for receiving engagement means of a like web of a vertically adjacent structural frame segment; and a plurality of bolt holes 812 and 814 for fastening to other connecting plates of adjacent structural frame segments. In use, the structural frame segment 800 is mounted to the building unit with the broad side of the trapezoidal connecting plate 804 closest to the building unit. Thus, the face 816 of the connecting plate 804 tapers (taper) towards the wall of the building unit to which it is attached.

Fig. 82 illustrates a plan view of the connection plate 804 to better show the shape of the connection plate 804. In the preferred form of this structural frame segment 800, the column elements 802 are mounted such that one surface thereof is generally aligned with the face 818 of the connector plate, and more preferably, the column elements 802 have edges 820 that are generally vertically aligned with the apex 822 of the trapezoidal connector plate 804. The reason for this preferred alignment will be explained below.

Fig. 83 illustrates three building unit assemblies 828, 830 and 832 to be positioned side by side to form a level of a building. Each of the building unit assemblies 828, 830 and 832 comprises a rectangular building unit to which four structural frame segments are attached. As can be seen, in the building unit assembly 828, the structural frame segments 834 and 836 are mounted such that their tapered sides 834A and 836A face inwardly toward each other. On the other side of the building unit, the structural frame sections 838 and 840 are mounted in an opposite manner such that their tapered faces 838A and 840A taper away from each other. In this way, the tapered face of the connecting plate acts like a tapered key assembly with respect to the horizontally adjacent building units. This keying effect between adjacent building unit assemblies makes it possible to accurately and easily locate the building unit assemblies with respect to each other on site.

Fig. 84A to 84C illustrate the manner in which adjacent building unit assemblies are brought together using this keying effect. In fig. 84A, two building unit assemblies 844 and 846 are positioned side-by-side and spaced apart from each other. In this position, the oppositely directed connecting plates 844A and 844B of the building unit assemblies 844 and 846 are aligned. In fig. 84B, as the building unit assemblies 844 and 846 are brought together, the tapered faces of the connecting plates 844A and 846A of the structural frame segments of the building unit assemblies 844 and 846, respectively, are brought together to join the two. The tapered faces provide angled guide surfaces and serve to guide the building unit assemblies 844 and 846 into correct relative alignment as the units are moved together. To illustrate the misalignment, in fig. 84B, the building unit assemblies 844 and 846 are misaligned a distance X. In this case, when properly aligned, the Z-stringers 850 and 852 will be aligned, although alignment of the structural frame sections is a critical factor for structural integrity, but for ease of illustration of the alignment distance, the stringers are referenced.

Turning now to fig. 84C, fig. 84C shows the final pinpointed positions of the building units 844 and 846. It can be seen that the building unit assembly is in a position such that the structural frame segments 844A and 846A are aligned along the column gap 854 between the building units and are substantially in contact along their tapered faces. They may now be joined together by bolting, welding or other methods as described elsewhere herein.

As can be seen in fig. 84A to 84C, the tapered faces of the connecting plates act as guide surfaces to facilitate horizontal alignment of the building units. However, in situations where the vertical alignment between building unit assemblies during positioning is poor, the outermost faces of the columns of the structural frame segments, and in particular the horizontally extending edges of the column elements which are generally aligned with the obtuse vertices of the trapezoidal connecting plates, also act as guide surfaces. Such vertical guidance is always required as the building unit assemblies are lowered into position by use of a crane. To further explain this, fig. 85 shows the same portions of the structural frame segment as shown in fig. 81, but with cross-hatching to illustrate those portions of the structural frame segment 800 that may be used as guide surfaces during assembly of a building.

To facilitate smooth guiding of the building unit assembly into position, the guide surfaces of the column elements 802 are substantially aligned with the guide surfaces of the connecting plates 804. It will be appreciated that perfect alignment is not necessarily required, particularly where there is only a small discontinuity in the guide surface, such as at the weld point between the column element 802 and the connection plate 804. In such cases, the weld itself tends to provide an angled surface that serves as part of the guide surface to relatively smoothly bridge the discontinuity when aligned. It will be appreciated that with this preferred alignment, even if two building units are brought into contact so that their connecting plates are not horizontally aligned, the guide surfaces 860 of the column element 802 will contact the guide surfaces of the corresponding connecting plates of the adjacent building units and make it possible to smoothly guide the building unit elements into the correctly aligned position as described above.

Advantages of embodiments of the system of the present invention include:

lightweight construction-the use of steel instead of concrete as a structural member in medium and high-rise constructions (and typically about 500 kg/m)²Typically about 200kg/m, compared to a standard concrete construction²)；

Fire protection-the building unit and the external structure are completely protected by the fire-resistant plasterboard from the fire source inside the building unit;

construction takes place inside the production facility and the building unit assemblies can be stacked in one, two or three levels;

the system allows the use of a wide range of workforce, including semi-skilled workers, apprentices and women;

the use of lower energy-light materials allows a substantial reduction in implementation energy;

and typically 500kg/m²Compared with the conventional concrete structure, the weight is estimated to be 200kg/m²Lighter building weight;

building the building unit assemblies off site within the production facility, using 50% less transportation energy, generating 75% less waste, and taking 50% less time than conventional building on site.

Since the outer periphery of one building unit is isolated from the outer periphery of the other building units, the sound isolation is higher than in normal construction. Physical contact between building units is only at the joints of the external structure, so that the system itself has a sound-insulating effect;

by replacing the conventional linear sequence of vertical construction with the ability to build building unit assemblies in a production facility in parallel while preparing or performing field work such as digging, footing, parking lot structures, concrete core and the like, the time of construction is greatly reduced;

has a higher degree of recyclability than a concrete structure. These components may be separated into their components in reverse order. The gypsum content can be recycled again as gypsum board, while the concrete must be broken up and used as aggregate or gravel. The building unit assembly comprises a general space structure which when disassembled can be used to build new structures with many potential uses.

The overall arrangement of the building can be built on the ground, so that a generally high degree of dimensional accuracy can be maintained and accurate installation during assembly is ensured.

The layout contained within the building unit is variable due to the fact that the wall position is not relevant to the structural system.

Many variations will be apparent to those of ordinary skill in the art without departing from the spirit and scope of the invention.

It is to be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternatives of the invention.

Claims (65)

1. A method of constructing a building having a plurality of levels using a plurality of building unit assemblies, wherein each building unit assembly is structurally self-supporting and has at least one side wall, a floor and a roof, the method comprising the steps of:

lifting the building unit assembly into position in the building such that each level of the building comprises a predetermined number of units;

connecting adjacent cells in each level to each other; and

a cell in one level is connected to a corresponding cell in at least one adjacent level vertically above or below the one level.

2. The method of claim 1, further comprising:

constructing at least one core wall; and

connecting units adjacent a core to the core configured such that vertical loads between adjacent levels are transmitted primarily through the building unit assembly and lateral loads can be transmitted to the core.

3. The method of construction of claim 1, further comprising:

attaching structural frame segments to at least one side wall of a building unit to form a building unit assembly; and

stacking the building unit assemblies to form levels of the building with structural frame segments in one level vertically aligned with structural frame segments in at least one adjacent level whereby substantially all vertical loads of the building unit assemblies are transmitted through the structural frame segments.

4. A method as claimed in claim 3 wherein lateral loads can be carried by the building units.

5. A method according to claim 3, wherein lateral loads can be carried by more than one core wall.

6. A method according to claim 4 or 5, wherein each of the structural frame segments comprises connecting plates at its top and bottom, and the method comprises: the top and bottom plates of the structural frame segments that are vertically adjacent to each other are connected together with fastening means.

7. A method of constructing a building as claimed in claim 3 wherein the structural frame segments are attached to the side walls of building units such that when a building unit is placed laterally adjacent another structural frame segment in a predetermined relative alignment, the structural frame segments of the building unit assembly are positioned side by side with the structural frame segments on the laterally adjacent building unit assembly; and the method includes the step of joining together structural frame segments positioned alongside one another.

8. The method of claim 7, wherein the step of connecting a cell in one level to a corresponding cell in a vertically adjacent level comprises: a step of connecting the top of the structural frame segment in the lower level to the bottom of the structural frame segment in the higher level.

9. The method according to claim 8, wherein the method comprises the steps of: mounting a top connection plate and a lower connection plate on the top end and the lower end of the column element, respectively; and connecting together the top webs of the structural frame segments positioned side-by-side with one another.

10. The method according to claim 9, wherein the method comprises the steps of: connecting the top connecting plate of the structural frame segments positioned side by side to one of the lower connecting plates of the structural frame segments positioned side by side to one another in an immediately adjacent upper level.

11. The method of claim 10, comprising the steps of: the other of the lower connector plates is clamped between vertically adjacent top connector plates by means of elongate clamping bars.

12. A building having a plurality of levels, the building comprising: a plurality of building unit assemblies, each of said plurality of building unit assemblies being structurally self-supporting and having at least one side wall, a floor and a roof; and structural frame segments attached to the at least one side wall of the building unit assembly, a plurality of sets of the building unit assemblies being stacked to form a level of the building and wherein the building unit assemblies are stacked such that the structural frame segments of one level are vertically aligned with structural frame segments in at least one adjacent level whereby substantially all vertical loads are transmitted through structural frame segments and lateral loads can be carried by the building unit assemblies.

13. A building as claimed in claim 12 wherein the building further comprises a core and the groups of building unit assemblies are arranged around and connected to the core such that vertical loads between adjacent levels are transmitted primarily through the building unit assemblies rather than through the core.

14. A building as claimed in claim 12 or 13 wherein the building further comprises one or more elongate connecting means extending between the top of a corresponding first structural frame segment attached to a building unit in one level to the top of a vertically aligned second structural frame segment attached to a building unit assembly in another level to enable the top of a first building element to be connected to the top of the second structural frame segment by the elongate connecting means.

15. A building as claimed in any one of claims 12 and 14 wherein a plurality of levels includes at least one building unit assembly placed in a first orientation and at least one second building unit assembly placed orthogonally to the first orientation such that the building unit assemblies in the first and second orthogonal orientations act as bracing to carry lateral loads.

16. A building as claimed in claim 12 wherein the ends of the column elements have mounting means connected thereto whereby the mounting means and structural frame section can be connected to adjacent panels of structural frame sections located substantially vertically above or below the one structural frame section.

17. A building as claimed in claim 16 wherein the mounting means comprises a top connecting plate and a lower connecting plate and wherein the position of the structural frame segments relative to the building units to which they are connected is such that: in a stage of the building at least some of the structural frame segments of adjacent building unit assemblies are located side by side in pairs with each other and wherein at least one lower connecting plate of a structural frame segment of another building unit assembly stacked above one of the adjacent building unit assemblies overlies at least a portion of the top connecting plate of the pair of structural frame segments, whereby the at least one lower connecting plate is connectable to the at least a portion of the top connecting plate of the pair of structural frame segments, thereby connecting the adjacent building unit assembly and the other building unit assembly together.

18. A building as claimed in claim 16 wherein the mounting means comprises a top connecting plate and a lower connecting plate and wherein the position of the structural frame segments relative to the building units to which they are connected is such that: within a level of the building at least some of the structural frame segments of adjacent building unit assemblies are located side by side with one another in pairs, the arrangement of the connecting plates being such that: for vertically aligned pairs of structural frame segments, at least three of their connecting plates can be connected together.

19. The building of claim 12, further comprising: first connecting means for connecting adjacent building unit assemblies within one level to each other;

and second connecting means for connecting a building unit assembly within one level to an adjacent building unit assembly level adjacent to said one level.

20. A building having a plurality of levels, at least some of the levels comprising a plurality of self supporting building units each having a structural frame segment connected thereto, the structural frame segment being adapted to support vertical loads of another level above the level, wherein:

the building comprises at least one higher level and one lower level, wherein the structural strength of the frame segments of the building units on the lower level is greater than the structural strength of the corresponding frame segments in the higher level.

21. The building of claim 20, wherein the building comprises a set of higher levels and a set of lower levels, wherein corresponding structural frame segments within the set of lower levels are substantially equal in structural strength and corresponding structural frame segments within the set of higher levels are substantially equal in structural strength.

22. A building as claimed in claim 21 wherein the structural strength of the structural frame segments in the lower set of levels is greater than the structural strength of the corresponding frame segments in the higher set of levels.

23. A building as claimed in any one of claims 20 to 22 wherein the structural frame segments are external to the self supporting building units.

24. A building as claimed in any one of claims 20 to 23 wherein the structural frame segments comprise column elements attached to the self supporting building units.

25. A building as claimed in any one of claims 20 to 24 wherein the building units are arranged within a level so as to define spaces between adjacent self supporting building units in which the structural frame segments are located.

26. A building as claimed in claim 25 wherein the spaces between vertically aligned pairs of adjacent self supporting building units are of substantially the same width.

27. A building as claimed in claim 26 wherein the spaces between all adjacent self supporting building units are of substantially the same width.

28. A building as claimed in any one of claims 25 to 27 wherein the structural frame elements all have substantially the same width transverse to the spaces between adjacent self supporting building units in which they are located.

29. A building according to claim 28, in which the relative difference in strength between two structural frame members is provided by varying at least one of the following factors:

the relative wall thicknesses of the structural frame members;

the relative depth of the structural frame members measured along the space between adjacent self supporting building units.

30. A structural frame segment for fitting to a self supporting building unit, the structural frame segment comprising:

at least one load bearing column element;

mounting means on each end of the structural frame segment for securing the structural frame segment to another similar self supporting building unit or building element.

31. A structural frame segment as claimed in claim 30 wherein the mounting means includes an engagement portion for engaging a matingly shaped engagement portion of a vertically aligned structural frame segment in use.

32. A structural frame segment as claimed in any one of claims 31 or 32 wherein the mounting means are connection plates attached to the ends of the column elements.

33. A structural frame segment as claimed in any one of claims 30 to 32 wherein at least one column element includes any one of a steel column or a concrete column.

34. A structural frame segment as claimed in claim 32 wherein, in use, the position of the column elements relative to the building units to which they are connected is such that: within a level of a building at least some of the column elements of adjacent building units are located side by side in pairs with each other and wherein at least one lower connecting plate of a column element of another building unit stacked above one of the adjacent building units overlies at least a portion of a top connecting plate of the pair of column elements, whereby the at least one lower connecting plate is connectable to the at least a portion of the top connecting plate of the pair of column elements, thereby connecting the adjacent building unit and the other building unit together.

35. A structural frame segment as claimed in claim 32 wherein the position of the column elements relative to the building units to which they are connected is such that: in a level of a building in which at least some of the column elements of adjacent building units are located side by side in pairs with each other, the arrangement of the connecting plates being such that: for vertically aligned pairs of columnar structures, at least three of their connection plates can be connected together.

36. A structural frame segment as claimed in any one of claims 30 to 35 wherein the structural frame segment has mounting means shaped to match the mounting means of a horizontally adjacent structural frame segment in use.

37. A structural frame segment as claimed in any one of claims 30 to 35 wherein the structural frame segment includes a plurality of column elements coupled by a means to distribute load between at least pairs of the plurality of columns.

38. A structural frame segment as claimed in any one of claims 30 to 37 comprising a guide surface to facilitate alignment with another building element.

39. A structural frame segment as claimed in claim 38 wherein the guide surface comprises at least a portion of a surface of the mounting means.

40. A structural frame segment as claimed in claim 38 or 39 wherein the guide surface comprises at least a portion of a column element.

41. A structural frame segment as claimed in any one of claims 30 to 40 wherein the mounting means includes an angled guide surface for guiding the mounting means into correct alignment with a correspondingly shaped mounting means in use.

42. A structural frame segment as claimed in any one of claims 38 to 41 wherein the guide surface includes a vertically extending portion which in use enables adjustment of the vertical alignment of the structural frame segment relative to another building or the like by sliding the guide surface against the building element.

43. A structural frame segment as claimed in any one of claims 30 to 42 wherein the mounting means includes at least one mounting plate including a tapered portion to provide an angled guide surface.

44. A structural frame segment as claimed in any one of claims 30 to 43 wherein the mounting means includes a generally trapezoidal plate which, in use, provides a tapered guide surface for a corresponding structural frame segment in horizontal alignment.

45. A structural frame segment as claimed in any one of claims 38 to 44 comprising at least one column element extending in a substantially perpendicular direction from a surface of the mounting plate and positioned such that: at least a portion of the surface of the column element is substantially aligned with the apex of the trapezoidal top plate forming part of the guiding surface of the mounting device and extends away from the trapezoidal top plate such that said portion of the surface of the column element provides a continuation of said guiding surface.

46. A method of constructing a building unit for constructing a building having a plurality of levels, the method comprising:

(a) the method comprises the following steps Constructing a self-supporting unit comprising a floor, a roof and at least one side wall, thereby defining an interior of the unit and an exterior of the unit;

(b) the method comprises the following steps At least one frame segment is attached to the exterior of the unit for structurally supporting a building unit assembly arranged in use above the building unit assembly.

47. The method of claim 46, wherein the method comprises:

(c) the method comprises the following steps Performing a stress relief step prior to step (b).

48. The method of claim 47, wherein step (a) comprises:

constructing the self-supporting unit with a jig or clamp; and wherein step (c) comprises releasing the clamping force applied by the clamp or vice.

49. The method of claim 47, wherein step (c) comprises: dissipating thermally conductive stresses in the self-supporting unit.

50. A method according to any one of claims 46 to 49, wherein step (a) comprises one or more of the following construction steps:

forming a floor from a plurality of floor panels;

forming at least one wall from a plurality of wall panels;

forming a frame from a plurality of frame members;

forming a roof from a plurality of roof panels;

attaching at least one of a wall, floor, or roof to the frame;

attaching at least one wall or wall member floor;

attaching a roof or at least one roof panel to at least one wall;

51. a method according to any one of claims 46 to 50 wherein the frame segment comprises a structural frame segment as claimed in any one of claims 30 to 45.

52. The method of any one of claims 46 to 51, wherein the method comprises: at least one datum point is defined on the exterior of the self-supporting unit with reference to one or more structural frame segments.

53. The method of claim 52, the method further comprising: arranging at least a part of the interior of the building unit with the at least one reference point as a reference.

54. The method of claim 52, wherein the method further comprises: attaching at least one facade element to the building unit assembly with the at least one datum as a reference.

55. The method of claim 54, wherein the method comprises: transferring measurements from the at least one reference point to an interior of the self-supporting unit.

56. A method of laying out a building having a plurality of levels, the method comprising:

designing a layout of the hierarchy;

defining a structural network of pillars common to a plurality of vertically adjacent levels;

a plurality of cells in each level are defined between columns of the network of columns such that the network of columns is located in spaces between horizontally adjacent cells.

57. The method of claim 56, further comprising:

the layout is adjusted to fit the space between the grid and horizontally adjacent cells.

58. The method of claim 56, further comprising:

a structural network of pillars common to all levels is defined.

59. The method of claim 56, further comprising:

a plurality of cylinder nets corresponding to the plurality of groups of levels is defined.

60. The method of claim 59, further comprising: the transfer structure is positioned between groups of levels forming a plurality of groups.

61. A method of constructing a building; the method comprises the following steps:

laying out a building using the method of any one of claims 56 to 60;

a plurality of self supporting building units corresponding to the laid out units are manufactured, wherein each self supporting building unit has attached thereto at least one associated structural support segment aligned with a defined network of columns.

62. The method of claim 61, further comprising: building at least one in situ component of the building.

63. The method of claim 62, further comprising: stacking a plurality of self supporting building unit assemblies in a defined configuration with the in situ component of the building; and connecting self supporting building unit assemblies together and to the self supporting building unit assemblies.

64. The method of any one of claims 61-63, further comprising: prior to building the building, a plurality of self supporting building unit assemblies are positioned in a relationship to each other as defined by the layout.

65. The method of claim 64, comprising: performing any of the following steps on the self supporting building unit assembly so positioned:

checking tolerances between at least some of the components of adjacent self supporting building unit assemblies;

verifying correct vertical and/or horizontal alignment between structural support segments of adjacent self supporting building unit assemblies;

arranging at least a portion of an interior of a self supporting building unit assembly;

temporarily connecting an auxiliary member between at least two self supporting building unit assemblies;

disconnecting the temporarily connected auxiliary elements from the self supporting building unit assembly;

mounting a facade or cladding member to a self supporting building unit assembly.