Modular building, prefabricated volume-module and method for production of a modular building

Abstract

The invention relates to a modular building of the type that comprises vertical frame columns ( 70 ) and a plurality of volume modules ( 2 ) prefabricated of sheet metal profiles ( 18 - 32 ) and being of rectangular horizontal section, which are supported by the columns ( 70 ) on two or more floor levels. The volume modules ( 2 ) are prefabricated with two frame edge beams ( 50 ) which are stronger than said sheet metal profiles ( 18 - 32 ) and which are horizontally extended along a respective upper end wall edge of the volume module ( 2 ) and which are on the one hand linearly connected with frame edge beams ( 50 ) of adjoining modules ( 2 ) on the same floor level and, on the other hand, connected to the columns ( 70 ) in such a manner that the horizontal position of the frame edge beams ( 50 ) relative to the columns ( 70 ) is fixed. The invention also relates to such a module and a method for manufacturing such a building.

1 . A modular building, comprising 
 a plurality of vertical frame columns and    a plurality of volume modules prefabricated of sheet metal profiles and having a rectangular horizontal section, which are supported by the columns on two or more floor levels,    wherein the volume modules are also prefabricated with two frame edge beams which are stronger than said sheet metal profiles and which are horizontally extended along a respective upper end wall edge of the volume module and which are on the one hand linearly connected with frame edge beams of adjoining modules on the same floor level and, on the other hand, connected to the columns in such a manner that the horizontal position of the frame edge beams relative to the columns is fixed.    
   
   
       2 . A modular building as claimed in  claim 1 , wherein the modules are supported by the columns in such a manner that they are vertically loaded only by their dead weight and payloads.  
   
   
       3 . A modular building as claimed in  claim 2 , wherein the modules are vertically supported at least in their lower corner portions by the columns while said frame edge beams transfer essentially only horizontal forces.  
   
   
       4 . A modular building as claimed in  claim 3 , wherein the modules rest on the flanges projecting horizontally from the columns.  
   
   
       5 . A modular building as claimed in  claim 4 , wherein each frame column consists of a number of separate column portions which each at the its lower end have a horizontally projecting, module-supporting flange.  
   
   
       6 . A modular building as claimed in  claim 4 , wherein the lower corner portions of the modules on the one hand and the module-supporting flanges of the columns on the other hand are provided with cooperating means which counteract lateral displacement of the modules.  
   
   
       7 . A modular building as claimed in  claim 1 , wherein each frame edge beam is positioned between two frame columns in a vertical plane common therewith.  
   
   
       8 . A modular building as claimed in  claim 7 , wherein each pair of two linearly interconnected frame edge beams has a first beam end and a second beam end which are positioned on either side of an intermediate frame column to form therewith a joint and which beam ends are directly connected with each other with the aid of a coupling means which bridges the frame column horizontally and on opposite sides thereof to thus also fix the horizontal position of the frame edge beams relative to the frame column.  
   
   
       9 . A modular building as claimed in  claim 8 , wherein each frame column is divided into linearly assembled column portions, and wherein said coupling means is formed as a separate coupling device, comprising on the one hand a horizontal top metal sheet which in the erection of the building is mounted between two column portions and, on the other hand, two vertical, mutually parallel connecting metal sheets which project downwards from the underside of the top metal sheet and which are extended on opposite sides of the frame column and connected with the beam ends of the frame edge beams.  
   
   
       10 . A modular building as claimed in  claim 1 , wherein the sheet metal profiles included in each module comprise two horizontal roof edge profiles which each form an upper longitudinal edge of the module and in which the two frame edge beams of the module are supported.  
   
   
       11 . A modular building as claimed in  claim 10 , wherein the frame edge beams and the two roof edge profiles are located in a common horizontal plane.  
   
   
       12 . A modular building as claimed in  claim 10 , wherein the frame edge beams are attached to the module in such a manner that horizontal forces can be transferred between the roof edge profiles and the frame edge beams perpendicular to the latter.  
   
   
       13 . A modular building as claimed in  claim 1 , further comprising horizontal, frame-stabilising surfaces in the form of panel elements and/or framework.  
   
   
       14 . A modular building as claimed in  claim 13 , wherein each module is prefabricated with a roof panel elements fixed to the frame edge beams of the module and wherein, on a given floor level, such floor panel elements are interconnected to a horizontal frame-stabilising surface.  
   
   
       15 . A modular building as claimed in  claim 1 , comprising vertical, frame-stabilising surfaces.  
   
   
       16 . A modular building as claimed in  claim 15 , wherein the modules are prefabricated with vertical wall elements, such as gypsum boards, to form said vertical frame-stabilising surfaces.  
   
   
       17 . A modular building as claimed in  claim 1 , wherein said sheet metal profiles have a material thickness of less than 4 mm.  
   
   
       18 . A modular building as claimed in  claim 1 , wherein said sheet metal profiles have a material thickness in the range 0.5-3 mm, preferably about 2 mm.  
   
   
       19 . A modular building as claimed in  claim 1 , wherein the columns and the frame edge beams are steel beams.  
   
   
       20 . A modular building as claimed in  claim 1 , wherein the columns and the frame edge beams are steel beams with a material thickness of at least 4 mm.  
   
   
       21 . A prefabricated volume module made of sheet metal profiles and having a rectangular horizontal section, which module, together with other such modules, is adapted to form a modular building in which the modules are vertically supported by frame columns on two or more floor levels, wherein the volume module is prefabricated with two frame edge beams which are stronger than said sheet metal profiles, said frame edge beams being horizontally extended along a respective upper end wall edge of the volume module and, in the modular building, linearly connected with frame edge beams of adjoining modules on the same floor level.  
   
   
       22 . A module as claimed in  claim 21 , wherein said sheet metal profiles comprise two horizontal roof edge profiles, which each form an upper longitudinal edge of the module and which support the frame edge beams at the upper end wall edges of the module.  
   
   
       23 . A module as claimed in  claim 22 , wherein each frame edge beam has two opposite free beam ends which are located horizontally outside the roof edge profiles and which, in the modular building, are connected with corresponding free beam ends of adjoining modules on the same floor level.  
   
   
       24 . A module as claimed in  claim 22 , wherein the two frame edge beams and the two roof edge profiles are located in a common horizontal plane.  
   
   
       25 . A module as claimed in  claim 24 , wherein the frame edge beams extend through vertical openings of the frame edge profiles so as to have said free beam ends on the outsides, directed away from each other, of the roof edge profiles.  
   
   
       26 . A module as claimed in  claim 21 , wherein the frame edge beams are attached to the module in such a manner that transfer of frame-stabilising horizontal forces is allowed between the roof edge profiles and the frame edge beams perpendicular to the latter.  
   
   
       27 . A module as claimed in  claim 26 , wherein each frame edge beam is attached to the two roof edge profiles by means of two horizontal tension rods, which each have an end connected with the frame edge beam and an end connected with the associated roof edge profile.  
   
   
       28 . A module as claimed in  claim 27 , wherein the roof edge profiles are formed as C profiles in which said tension rods are extended.  
   
   
       29 . A module as claimed in  claim 21 , wherein the module is further provided with one or more frame-stabilising surfaces in the form of panel elements and/or framework.  
   
   
       30 . A module as claimed in  claim 21 , wherein the module is provided with a frame-stabilising surface in the form of a horizontal-force-transferring roof panel element which is fixed to the two frame edge beams.  
   
   
       31 . A module as claimed in  claim 30 , wherein said horizontal-force-transferring roof panel element is made of trapezoidal metal sheet.  
   
   
       32 . A module as claimed in  claim 30 , wherein said horizontal-force-transferring roof panel element is fixed also to at least some profiles among said sheet metal profiles which form the roof of the module.  
   
   
       33 . A module as claimed in  claim 21 , wherein the module is provided with a frame-stabilising surface in the form of a horizontal-force-transferring roof framework.  
   
   
       34 . A module as claimed in  claim 21 , wherein the module is provided with one or more frame-stabilising surfaces in the form of vertical-force-transferring wall panel elements which are fixed to the sides of the module.  
   
   
       35 . A module as claimed in  claim 34 , wherein said wall panel elements comprise gypsum boards.  
   
   
       36 . A module as claimed in  claim 21 , wherein said sheet metal profiles have a material thickness of less than 4 mm.  
   
   
       37 . A module as claimed in  claim 36 , wherein said sheet metal profiles have a material thickness in the range 0.5-3 mm, preferably about 2 mm.  
   
   
       38 . A module as claimed in  claim 21 , wherein the frame edge beams are steel beams.  
   
   
       39 . A module as claimed in  claim 38 , wherein the frame edge beams are steel beams with a material thickness exceeding 4 mm.  
   
   
       40 . A module as claimed in  claim 21 , wherein the frame edge beams and the columns have essentially the same horizontal width.  
   
   
       41 . A module as claimed in  claim 21 , wherein, in the modular building, the lower corner portions of the module are supported by flanges projecting horizontally from the columns, and wherein the module further comprises means at its lower corner portions adapted to cooperate with said flanges to prevent horizontal displacement of the module relative to the columns.  
   
   
       42 . A modular building comprising a plurality of modules as claimed in any one of claims  21 - 41 , wherein frame edge beams of adjoining modules on the same floor level are linearly interconnected so as to jointly transfer horizontal compressive forces and tensile forces in the building.  
   
   
       43 . A method for manufacturing a modular building, comprising the following steps 
 prefabricating rectangular volume modules of sheet metal profiles, each module also being prefabricated with two frame edge beams which are stronger than the sheet metal profiles and which are horizontally extended along a respective upper end wall edge of the module; and    mounting at the building site the prefabricated volume modules on two or more floor levels by means of vertical frame columns, frame edge beams of adjoining modules on each floor level being interconnected linearly before the modules of the next floor level are mounted.    
   
   
       44 . A method as claimed in  claim 43 , wherein the modules are mounted so that they are vertically loaded only by their dead weight and payloads.  
   
   
       45 . A method as claimed in  claim 44 , wherein each frame column is divided into a number of column portions corresponding to the number of floor levels, and wherein frame edge beams of adjoining modules on each floor level are interconnected linearly and connected with the column portions of the floor level before the column portions and the modules of the next floor level are mounted.  
   
   
       46 . A method as claimed in  claim 45 , wherein each column portion has at its lower end a horizontally projecting bottom flange, and wherein the step of mounting the volume modules comprises the following substeps for each floor level before the next floor level is mounted: 
 mounting the column portions belonging to the floor level,    arranging the modules belonging to the floor level on top of the bottom flanges of the column portions belonging to the floor level,    linearly interconnecting the frame edge beams of adjoining modules, and connecting the beam ends of the frame edge beams with the column portions belonging to the floor level.    
   
   
       47 . A method as claimed in  claim 46 , wherein the substep of interconnecting the frame edge beams of two adjoining modules and the substep of connecting the beam ends of the frame edge beams with the column portions are carried out as a common substep by mounting a coupling means which is common for these interconnections.  
   
   
       48 . A method as claimed in  claim 47 , wherein the frame edge beams are positioned between the frame columns in vertical planes common therewith, so as to form joints where two opposite beam ends are arranged on either side of a frame column and interconnected linearly round the frame column by the common coupling means so that the horizontal position of the frame edge beams relative to the columns is fixed.  
   
   
       49 . A method as claimed in  claim 43 , wherein the step of prefabricating the volume modules comprises the following substeps: 
 manufacturing an open volume of sheet metal profiles, comprising two horizontal roof edge profiles which each form an upper longitudinal edge of the module and which have vertical openings at the end walls ( 6 ) of the module, and    mounting the frame edge beams in the vertical openings of the frame edge profiles so that the frame edge beams on the outsides, directed away from each other, of the roof edge profiles have free beam ends for linear connection with such free beam ends of the frame edge beams of adjoining modules.