WO2014068292A2

WO2014068292A2 - A modular construction system

Info

Publication number: WO2014068292A2
Application number: PCT/GB2013/052805
Authority: WO
Inventors: William George Hunter
Original assignee: AGILE STRUCTURES Ltd
Current assignee: AGILE STRUCTURES Ltd
Priority date: 2012-10-29
Filing date: 2013-10-28
Publication date: 2014-05-08
Anticipated expiration: 2015-04-29
Also published as: GB2508974A; GB2508974B; GB201219376D0; GB201318999D0; WO2014068292A3

Abstract

A modular construction system includes an elongate construction element comprising an elongate body including a longitudinal web. The web defines opposite first and second edges and a longitudinal centreline. The first and second edges are spaced from the longitudinal centreline by a pre-determined distance. A longitudinal first flange of uniform width extends transverse to the web along the first edge in a first plane, and defines a flange edge at a pre-set separation from the web. The elongate body defines opposite first and second ends, and the elongate body has, at the first end, a first end plate orthogonal to the longitudinal centreline. The first end plate defines a first aperture at a selected distance from the first plane. The first aperture is provided in the plane of the web. The web defines at least one second aperture at the same selected distance from the first plane. The first flange terminates at a flange end short of the first end by a distance at least equal to the pre-set separation, whereby the first end of the elongate construction element may be coupled to the web of a second such elongate construction element with the first end plate of the first elongate construction element in facial contact with the web of the second such elongate construction element by a bolt and nut combination, the bolt having a shaft arranged to extend through both the first aperture of the first elongate construction element and a second aperture of the second elongate construction element.

Description

A MODULAR CONSTRUCTION SYSTEM

Background

This disclosure relates to a modular construction system. More particularly, but not necessarily exclusively, it relates to modular construction systems for forming knockdown modular structures, for example, but without restriction: a stage or an exhibition stand.

Construction and knockdown times for knockdown modular structures can have significant cost implications. Shorter times may result in reduced labour costs and, in cases where such structures are rented, may reduce rental costs. One previously proposed modular construction system is disclosed in

WO2006/086803 Hunter. This modular construction system involved use of a construction element in the form of a beam which has an elongate body with a first side, an opposing second side, a first end, an opposing second end, a web which extends in a first direction from the second end to the first end and in a first plane, and a first flange which is fixed to the web at the first side, a first mounting which is fixed to the first end and which has an abutment formation located between the first side and the second side and a receiving formation which extends in the first direction, and a first access formation in the web at the first end to allow access to the receiving formation.

Another modular construction system is disclosed in WO2009/144484 Rapid Space Ltd. This modular construction system includes an elongate construction element with an elongate body including a longitudinal web, opposite first and second edges, a longitudinal first flange transverse to the web along a first edge, opposite first and second ends, a first end plate orthogonal to the web with a first hole, a second hole intermediate the first hole and the first edge, and a third hole intermediate the first hole and the second edge. For each of the holes, a cut-out is provided in the web.

Both of these prior modular construction systems, for which the Inventor was the same as the Inventor for the present disclosure, generally work well. However, they both require the use of additional connectors, over and above a simple bolt and nut combination, when connections are to be made between an end of one construction element and an end of a second construction element via an opening in the web of a third such element, or when connecting an end of one construction element to an opening in the web of a second such element.

Another modular construction system is disclosed in JP6-288005. This system uses a construction element in the form of a beam which has an elongate body with a first side, an opposing second side, a first end, an opposing second end, a web which extends in a first direction from the second end to the first end and in a first plane, and a first flange which is fixed to the web at the first side and a second flange which is fixed to the web on the second side. An L-shaped connector is coupled to the first end. This results in an abutment formation effectively being provided at the first end, but only on the first side. This abutment formation can be placed directly against the web of another beam allowing the two beams to be joined using only nuts and bolts. Coupling an L-shaped connector to the web may result in weaknesses leading to failure with repeated use. Most significantly, the nuts and bolts can only be supplied to the abutment formation from one side of the beam, restricting application of the system, and extending erection and deconstruction times.

Summary of the Disclosure

According to a first aspect of this disclosure, there is provided a modular construction system including an elongate construction element, the element comprising: an elongate body including a longitudinal web; the web defining opposite first and second edges and a longitudinal centreline, the first and second edges being spaced from the longitudinal centreline by a pre-determined distance; a longitudinal first flange of uniform width extending transverse to the web along the first edge in a first plane, and defining a flange edge at a pre-set separation from the web; the elongate body defining opposite first and second ends, and the elongate body having, at the first end, a first end plate orthogonal to the longitudinal centreline; the first end plate defining a first aperture at a selected distance from the first plane, said first aperture being provided in the plane of the web, and the web defining at least one second aperture at the same selected distance from the first plane; and the first flange terminating at a flange end short of the first end by a distance at least equal to the pre-set separation, whereby the first end of the elongate construction element may be coupled to the web of a second such elongate construction element with the first end plate of the first elongate construction element in facial contact with the web of the second such elongate construction element by a bolt and nut combination, the bolt having a shaft arranged to extend through both the first aperture of the first elongate construction element and a second aperture of the second elongate construction element.

Preferred embodiments may have one or more of the following features: The first flange terminates short of the first end by a distance substantially equal to the pre-set separation, whereby, with the first end of the elongate construction element coupled to the web of a second such elongate construction element by a bolt and nut combination with the first end plate of the first elongate construction element in facial contact with the web of the second such elongate construction element and the shaft of the bolt extending through both the first aperture of the first elongate construction element and the second aperture of the second elongate construction element, the respective first flanges of the first and second elongate construction elements form a substantially continuous surface with the flange end of the first flange of the first elongate construction element substantially abutting the flange edge of the first flange of the second elongate construction element. The first aperture and the second aperture lie on the longitudinal centreline. The first end plate defines a plurality of first apertures at different selected distances from the first plane and the web defines at least one second aperture at each of the different selected distances from the first plane. For the or each first aperture there is a corresponding cut-out in the web adjacent the first end plate for insertion of a shaft of a bolt through the first aperture whilst accommodating the head of the bolt. A longitudinal second flange of uniform width extends transverse to the web along the second edge in a second plane. The width of the second flange is the same as that of the first flange, the second flange defining a flange edge at the same pre-set separation from the web as that of the first flange; and the second flange terminates at a flange end short of the first end by the same distance as first flange. The elongate body has, at the second end, a second end plate orthogonal to the longitudinal centreline, the second end plate defining a third aperture at the same selected distance from the first plane as the first aperture; and the first flange terminating at a flange end short of the second end by the same distance as it terminates short of the first end. The first end plate terminates at a plate edge short of the first plane, and the web defines an edge extending from the plate edge to the flange end with a third flange provided at said web edge, the third flange joining the first flange to the first end plate. In the most preferred arrangement, the elongate element is symmetrical about its longitudinal centreline, having a second flange that is the mirror image of the first flange, and having a second end that is the mirror image of the first, the first end plate having two first apertures located at selected distances from the first plane equal to one- third and two-thirds of the separation between the two flanges.

The modular construction system will suitably include a plurality of such elongate construction elements, possibly together with other construction elements, for example: bracing elements, and nut and bolt combination fasteners for securing the construction elements together. The system may then be used to custom build modular knockdown structures of various configurations suitable for different purposes. Although the system was conceived for building temporary structures, permanent structures may also be built from the system.

According to a second and alternative aspect of this disclosure, there is provided a construction in modular form comprising at least a first elongate construction element and a second elongate construction element coupled together; both the first elongate construction element and the second elongate construction element comprising: an elongate body including a longitudinal web, the web defining opposite first and second edges and a longitudinal centreline, the first and second edges being spaced from the longitudinal centreline by a pre-determined distance, a longitudinal first flange of uniform width extending transverse to the web along the first edge in a first plane, and defining a flange edge at a pre-set separation from the web, the elongate body defining opposite first and second ends, and the elongate body having, at the first end, a first end plate orthogonal to the longitudinal centreline, the first end plate defining a first aperture at a selected distance from the first plane, said first aperture being provided in the plane of the web, and the web defining at least one second aperture at the same selected distance from the first plane, and the first flange terminating at a flange end short of the first end by a distance at least equal to the pre-set separation; the first end of the first elongate construction element being coupled to the web of the second elongate construction element with the first end plate of the first elongate construction element in facial contact with the web of the second elongate construction element by a bolt and nut combination, the bolt having a shaft arranged extending through both the first aperture of the first elongate construction element and a second aperture of the second elongate construction element.

Brief Description of the Drawings

Preferred embodiments are described hereinbelow by way of example only with reference to the accompanying drawings, in which: Fig. 1 is a side view of one end of an elongate construction element of a modular construction system;

Fig. 2 is a top view of the one end of the element of Fig. 1 ;

Fig. 3 is a side view of one end of an alternative elongate construction element of a modular construction system; Fig. 4 is a top view of the one end of the element of Fig. 3;

Fig. 5 is a side view of an assembly in which two elements as shown in Fig. 1, are secured together end-to-end with the web of a third such element secured between them;

Fig. 6 is a side view of a similar assembly to that of Fig. 5 employing elements as shown in Fig. 3; Fig. 7 is a view similar to that of Fig. 6, in which one of the elements is substituted by an element as shown in Fig. 1;

Fig. 8 is a view similar to that of Fig. 7, in which a further element is substituted by an element as shown in Fig. 1; and

Fig. 9 is a top view of the assembly of Fig. 5. Description of Preferred Embodiments

An elongate construction element 1, shown in Figs. 1 and 2 has an elongate body 2 including a longitudinal web 3. The web 3 defines opposite first and second edges 4 and 5 and a longitudinal first centreline 6. The first and second edges 4 and 5 are spaced from the longitudinal centreline 6 by a pre-determined distance. A longitudinal first flange 7 of uniform width extends transverse to the web 3 along the first edge 4 in a first plane and a longitudinal second flange 8, here of the same uniform width as the first flange extends transverse to the web 3 along the second edge 5 in a second plane. The first and second flanges define flange edges 9 at a pre-set separation S from the web 3.

The elongate body 2 defines opposite first 10 and second ends (the second end not being shown in these drawings, but preferably being the mirror image of the first). At the first end 10 there is a first end plate 11 orthogonal to the longitudinal centreline 6. The first end plate 11 defines a first aperture 12 in the plain of the web and at a selected distance from the first plane, here on the longitudinal centreline 6.

The web 3 is formed with at least one aperture 13, and preferably a series of apertures along its length, all at the same selected distance as aperture 12 from the first plane. In the element 1 shown in Figs. 1 and 2, apertures 13 lie on the longitudinal centreline 6. However, it is not necessary that apertures 13, and also aperture 12, should lie on the longitudinal centreline. As explained below with reference to Figs. 3 and 4, there may be several apertures 12 in first end plate 11 at different selected distances from the plane of the first flange 7, with corresponding apertures 13 at the same different selected distances in the web. As can be seen from Fig. 1, the first flange 7 terminates at a flange end 14 short of the first end 10 by a distance D. This distance is at least equal to the pre-set separation S for reasons that will become apparent below.

To allow for insertion of a shaft of a bolt into aperture 12 and to accommodate the head of the bolt or a nut if the bolt is inserted from the other side of first end plate 11 , the web is formed with a cut-out 15 adjacent aperture 12.

The first end plate 11 terminates at a plate edge 16 short of the first plane, and web 3 defines an edge 17 which extends from the plate edge 16 to the flange end 14, with a third flange 18 provided on edge 17 joining the first flange 7 to the first end plate 11. The first end plate 11 also terminates short of the second plane, and the web 3 defines a further edge 19 with a fourth flange 20 joining the second flange 8 to the first end plate 11.

On both its first and second flanges 7 and 8, elongate construction element 1 is provided with at least one securing formation 21 for securing element 1 to another element, for example, another elongate construction element 1 via one of its flanges. The securing formation 21 comprises an aperture 22 defined in the respective flange, together with a cut-out 23 formed in the web 3 adjacent the aperture 22. The cut-out enables insertion of the shaft of a bolt through the aperture 22 and accommodation of the head of the bolt or of a nut. As shown in Fig. 6, the securing formation may include a nut 24 permanently fitted to the flange within the cut-out 23 and in register with the aperture 22.

Figs. 3 and 4 show a second embodiment 25 of elongate construction element. Like reference numerals are employed for like features to those of the embodiment of Figs. 1 and 2. First end plate 11 is here provided with two apertures 12, 12', aperture 12' being at a selected distance from the plane of the first flange that is double that of aperture 12. Elongate construction element 25 is symmetrical about its longitudinal centreline 6, and so the respective distances of the apertures 12 and 12' from the plane of the first flange are respectively one-third and two-thirds of the separation between the first and second flanges. There are corresponding apertures 13, 13' in the web 3 at the same selected distances as apertures 12, 12' . A practical construction system will include a plurality of elongate construction elements such as elements 1 and 25, together with fastening means for coupling one such element to another. As will become clear from the description below, in general, the only such fastening means required will be nut and bolt combinations. The system may be employed to custom build modular knockdown structures of various configurations suitable for different purposes. Although the system was conceived for building temporary structures, permanent structures may also be built from the system.

Fig. 5 shows how two elongate construction elements 1, as shown in Figs. 1 and 2, may be secured together end-to-end with the web of a third such element secured between them. A bolt 26 having a head 27 and shaft 28 is inserted through aperture 12 in first end plate 11 of a first such elongate construction element 29, cut-out 15 allowing this, through an aperture 13 in the web 3 of intermediate elongate construction element 30, and through aperture 12 in first end plate 11 of the second such elongate construction element 31.

Fig. 6 shows, on a larger scale, a similar construction employing three elongate construction elements 32, 33 and 34. Because the distance D by which the respective first flanges 7 terminate short of the respective first ends is at least equal to the pre- set separation S by which flange edges 9 are separated from the web 3, the respective first end plates 11 of the first 29, 32 and second 31, 34 elongate construction elements can make facial contact with the web 3 of the intermediate elongate construction element 30, 33, so that no additional spacer or other fastener means apart from a simple nut and bolt combination is needed. In the embodiments of Figs. 5 and 6, the respective elongate construction elements are all I- shaped in section, and the distance D is substantially equal to the pre-set separation S. As a result the coupled construction elements of Figs. 5 and 6 provide near continuous flange surfaces from the first 29, 32 to the second 31, 34 elongate construction elements via the surface of first flange of the intermediate elongate construction element 30, 33.

By choosing sets of elongate construction elements that include both elements 1 and 25 that have the same selected distances of respective apertures 12 from the closest adjacent flange in the different embodiments, combination structures in various configurations may be produced, as shown by way of example in Figs. 7 and 8, where there is essentially continuity between the first flange of one element and that of a second element extending at right angles to the one element. This continuity is further illustrated by the top plan view of Fig. 9 showing the combination of elements shown in Fig.5.

Although not illustrated in any of the present drawings, it will be readily understood that the provision of securing formations on the respective flanges, enables embodiments of construction elements 1 and 25 to be coupled facially flange-to-flange, again with no more than a nut and bolt combination.

Although the elongate body of each of the elongate construction elements illustrated in the drawings has an I-shaped section in which there are two flange edges to each flange, each separated from the web by the same pre-set separation S, this is not necessary, since the same advantage that an end plate of one elongate construction element may be fastened to the web of a second such element or to the end plate of a third such element via the web of a second, by a simple nut and bolt combination without additional fastening elements, and with the end plate in facial contact with the web, with elongate construction elements with any of L-, C-, J or a T-cross-section (in other words: with just one flange on one side of a web; with two flanges on the same side of a web; with two flanges, one of which is on both sides of the web, and the other on only one side; and with one flange on both sides of the web) provided that the flange terminates at a flange end short of the associated end of the elongate construction element by a distance at least equal to the pre-set separation of a flange edge from the associated web.

Where the elongated body has an L- C-cross-section, the flange should terminate short of the associated end of the element by a distance at least equal to the width of the flange.

Where the elongated body has a T- or I-cross-section, the flange(s) terminates short of the associated end of the element by a distance that is about half the width of the flange or more.

Claims

A modular construction system including an elongate construction element, the element comprising: an elongate body including a longitudinal web; the web defining opposite first and second edges and a longitudinal centreline, the first and second edges being spaced from the longitudinal centreline by a pre-determined distance; a longitudinal first flange of uniform width extending transverse to the web along the first edge in a first plane, and defining a flange edge at a pre- set separation from the web; the elongate body defining opposite first and second ends, and the elongate body having, at the first end, a first end plate orthogonal to the longitudinal centreline; the first end plate defining a first aperture at a selected distance from the first plane, said first aperture being provided in the plane of the web, and the web defining at least one second aperture at the same selected distance from the first plane; and the first flange terminating at a flange end short of the first end by a distance at least equal to the pre- set separation, whereby the first end of the elongate construction element may be coupled to the web of a second such elongate construction element with the first end plate of the first elongate construction element in facial contact with the web of the second such elongate construction element by a bolt and nut combination, the bolt having a shaft arranged to extend through both the first aperture of the first elongate construction element and a second aperture of the second elongate construction element.

A modular construction system according to Claim 1, wherein the first flange terminates short of the first end by a distance substantially equal to the pre-set separation whereby, with the first end of the elongate construction element coupled to the web of a second such elongate construction element by a bolt and nut combination with the first end plate of the first elongate construction element in facial contact with the web of the second such elongate construction element and the shaft of the bolt extending through both the first aperture of the first elongate construction element and the second aperture of the second elongate construction element, the respective first flanges of the first and second elongate construction elements form a substantially continuous surface with the flange end of the first flange of the first elongate construction element substantially abutting the flange edge of the first flange of the second elongate construction element. A modular construction system according to Claim 1, wherein the first aperture and the second aperture lie on the longitudinal centreline.

A modular construction system according to Claim, wherein the first end plate defines a plurality of first apertures at different selected distances from the first plane and the web defines at least one second aperture at each of the different selected distances from the first plane.

A modular construction system according to Claim 1 , wherein for the or each first aperture there is a corresponding cut-out in the web adjacent the first end plate for insertion of a shaft of a bolt through the first aperture whilst accommodating the head of the bolt.

A modular construction system according to Claim 1, wherein a longitudinal second flange of uniform width extends transverse to the web along the second edge in a second plane, the width of the second flange being the same as that of the first flange, and the second flange defining a flange edge at the same pre-set separation from the web as that of the first flange; and the second flange terminates at a flange end short of the first end by the same distance as the first flange.

A modular construction system according to Claim 1, wherein the elongate body has, at the second end, a second end plate orthogonal to the longitudinal centreline, the second end plate defining a third aperture at the same selected distance from the first plane as the first aperture; and the first flange terminating at a flange end short of the second end by the same distance as it terminates short of the first end.

A modular construction system according to Claim 1, wherein the first end plate terminates at a plate edge short of the first plane, and the web defines an edge extending from the plate edge to the flange end with a third flange provided at said web edge, the third flange joining the first flange to the first end plate.

A modular construction system according to Claim 1, wherein the elongate element is symmetrical about its longitudinal centreline, having a second flange that is the mirror image of the first flange, and having a second end that is the mirror image of the first, the first end plate having two first apertures located at selected distances from the first plane equal to one-third and two-thirds of the separation between the two flanges.

10. A modular construction system according to Claim 1, including a plurality of the said elongate construction elements, together with bracing elements, and nut and bolt combination fasteners for securing the construction elements together.

11. A construction in modular form comprising at least a first elongate construction element and a second elongate construction element coupled together; both the first elongate construction element and the second elongate construction element comprising: an elongate body including a longitudinal web, the web defining opposite first and second edges and a longitudinal centreline, the first and second edges being spaced from the longitudinal centreline by a pre-determined distance, a longitudinal first flange of uniform width extending transverse to the web along the first edge in a first plane, and defining a flange edge at a pre-set separation from the web, the elongate body defining opposite first and second ends, and the elongate body having, at the first end, a first end plate orthogonal to the longitudinal centreline, the first end plate defining a first aperture at a selected distance from the first plane, said first aperture being provided in the plane of the web, and the web defining at least one second aperture at the same selected distance from the first plane, and the first flange terminating at a flange end short of the first end by a distance at least equal to the pre-set separation; the first end of the first elongate construction element being coupled to the web of the second elongate construction element with the first end plate of the first elongate construction element in facial contact with the web of the second elongate construction element by a bolt and nut combination, the bolt having a shaft arranged extending through both the first aperture of the first elongate construction element and a second aperture of the second elongate construction element.

12. A construction according to Claim 11, wherein the first flange of the first construction element terminates short of the first end by a distance substantially equal to the pre-set separation whereby, the respective first flanges of the first and second elongate construction elements form a substantially continuous surface with the flange end of the first flange of the first elongate construction element substantially abutting the flange edge of the first flange of the second elongate construction element.