Modular construction system

Abstract

A modular construction system is described. The system includes blocks ( 1 ) composed of structural slabs ( 4 ) and spacers ( 5 ), with the spacers ( 5 ) being arranged to form orthogonal and diagonal cavities ( 6, 7 ) extending within the blocks ( 1 ). When a number of blocks 1 are combined, the cavities combine to extend across blocks. Reinforcing members in the form of joists ( 8 ) can be located within the cavities, together with fastening members, to secure the construction. The principal system components may be manufactured from second-grade and/or reclaimed wood-based products and the like, to provide an inexpensive construction material. Additional cladding members or fascias can be mounted to the slabs ( 4 ), to alter aesthetic appearance or to provide functional properties such as insulation.

1 . A modular construction system comprising blocks forming basic units of construction that may be assembled to form structures, the blocks each comprising paired structural slabs and at least one spacer separating the paired slabs to form a void therebetween, wherein when assembled the voids of one or more blocks define at least one continuous cavity along at least two axes of the one or more blocks for receiving at least one reinforcing member and wherein the edges of the slabs present a connecting surface for connection to a structural slab in at least one other identical block.  
   
   
       2 . The system of  claim 1 , wherein the cavity is defined by the voids of a plurality of blocks.  
   
   
       3 . The system of  claim 2 , wherein the cavity extends substantially continuously through the blocks.  
   
   
       4 . The system of  claim 1 , wherein the cavity is defined between the spacers of the blocks.  
   
   
       5 . The system of  claim 1 , wherein the spacers are encircled by the voids.  
   
   
       6 . The system of  claim 1 , wherein a plurality of cavities are defined.  
   
   
       7 . The system of  claim 6 , wherein the plurality of cavities are interconnected with one another.  
   
   
       8 . The system of  claim 6 , wherein the plurality of cavities lies along different axes of the blocks.  
   
   
       9 . The system of  claim 6 , wherein the plurality of cavities lies along parallel axes of the blocks.  
   
   
       10 . The system of  claim 1 , wherein cavities extend along a plurality of axes of the blocks.  
   
   
       11 . The system of  claim 10 , wherein cavities extend along at least three axes of the blocks.  
   
   
       12 . The system of  claim 10 , wherein cavities extend along at least four axes of the blocks.  
   
   
       13 . The system of  claim 12 , wherein cavities extend along two orthogonal axes of the block and along two diagonal axes of the block.  
   
   
       14 . The system of  claim 13 , wherein the various axes of the block are spaced at 45 degree angles from one another.  
   
   
       15 . The system of  claim 1 , wherein the cavities are of modular dimensions.  
   
   
       16 . The system of  claim 1 , wherein each block further defines a cavity extending perpendicular to the block.  
   
   
       17 . The system of  claim 16 , wherein the perpendicular cavity is defined by a void provided within the spacer.  
   
   
       18 . The system of  claim 16 , wherein the perpendicular cavity is created in use.  
   
   
       19 . The system of  claim 1 , wherein the blocks define cavities extending in five axes within which reinforcing members may be received.  
   
   
       20 . The system of  claim 1 , wherein the blocks define a regular shape.  
   
   
       21 . The system of  claim 20 , wherein the blocks are generally quadrilateral in shape.  
   
   
       22 . The system of  claim 1 , wherein each block comprises a plurality of spacers.  
   
   
       23 . The system of  claim 22 , wherein the plurality of spacers are regularly arranged within each block.  
   
   
       24 . The system of  claim 1 , wherein the spacers are generally octagonal in shape.  
   
   
       25 . The system of  claim 1 , wherein the spacers comprise blocks located between slabs or further blocks.  
   
   
       26 . The system of  claim 1 , wherein the spacers are comprised of a material selected from the group consisting of: wood, wood derivatives, block-board, plywood, structural building boards or panels, other organic or inorganic fibrous tissue, paper, paperboards, cardboards, pasteboards; plastics; polymers; metals; concrete; and stone.  
   
   
       27 . The system of  claim 1 , wherein the slabs are formed of a cuttable material.  
   
   
       28 . The system of  claim 27 , wherein the slabs are formed of a material derived from wood including engineered woods such as block-board, plywood, structural building boards or panels, other organic or inorganic fibrous tissue, or the like.  
   
   
       29 . The system of  claim 28 , wherein the slabs are formed of materials that incorporate reclaimed or other low-grade wood material.  
   
   
       30 . The system of  claim 29 , wherein the slabs are formed of oriented strand board.  
   
   
       31 . The system of  claim 1 , wherein the slabs are formed from a material selected from the group consisting of: paper, paperboards, cardboards, pasteboards; plastics; polymers; metals; concrete; and stone.  
   
   
       32 . The system of  claim 1 , wherein the slabs include cavities, corrugations, foams, or cells.  
   
   
       33 . The system of  claim 1 , further comprising one or more reinforcing members for being received into the cavity of the blocks.  
   
   
       34 . The system of  claim 33 , wherein the reinforcing members comprise joists for extending through a cavity.  
   
   
       35 . The system of  claim 34 , wherein the joists comprise I-beams.  
   
   
       36 . The system of  claim 34 , wherein the joists comprise webs having apertures for receiving fastening members for fastening joists to other components of the system.  
   
   
       37 . The system of  claim 33 , wherein the reinforcing members are comprised of a material selected from the group consisting of: wood, wood derivative, block-board, plywood, structural building boards or panels, other organic or inorganic fibrous tissue, paper, paperboards, cardboards, pasteboards; plastics; polymers; metals; concrete; and stone.  
   
   
       38 . The system of  claim 33 , wherein the reinforcing members comprise clamps for engaging with spacers.  
   
   
       39 . The system of  claim 33 , wherein the reinforcing members comprise fastening members, such as bolts, chains, ties or wires.  
   
   
       40 . The system of  claim 33 , wherein the reinforcing members comprise straps or the like, for securing around spacers.  
   
   
       41 . The system of  claim 40 , wherein the straps further comprise locking members.  
   
   
       42 . The system of  claim 1 , wherein the blocks further comprise engaging means for engaging adjacent blocks together.  
   
   
       43 . The system of  claim 42 , wherein the engaging means comprises corresponding protrusions and recesses provided on the blocks.  
   
   
       44 . The system of  claim 1 , wherein the blocks further comprise securing means for securing adjacent blocks and/or reinforcing members together.  
   
   
       45 . The system of  claim 1 , wherein the blocks further comprise non-structural layers.  
   
   
       46 . The system of  claim 45 , wherein the non-structural layers comprise any or all of cladding, insulation, fire-retardant, waterproofing, aesthetic layers, and soundproofing.  
   
   
       47 . The system of  claim 45  wherein the non-structural layer is provided externally of the structural slabs.  
   
   
       48 . The system of  claim 45  wherein the non-structural layer is removable.  
   
   
       49 . The system of  claim 1 , wherein multiple blocks are combined to form a building unit.  
   
   
       50 . The system of  claim 1 , wherein the spacers and slabs are formed from separate components.  
   
   
       51 . The system of  claim 1 , further comprising wedge-shaped members.  
   
   
       52 . The system of  claim 1 , further comprising a granular, foam-based, or flowing material located within at least one cavity.  
   
   
       53 . A block for use in a modular construction system, the block comprising paired structural slabs and at least one spacer separating the paired slabs to form a void therein, wherein the void defines at least one cavity along at least two axes of the block for receiving at least one reinforcing member.  
   
   
       54 . A kit for forming structures, the kit comprising a plurality of blocks which may be assembled to form structures, the blocks comprising paired structural slabs and at least one spacer separating the paired slabs to form a void therebetween, wherein when assembled the voids of one or more blocks define at least one continuous cavity along at least two axes of the block for receiving at least one reinforcing member; in combination with a plurality of reinforcing members.  
   
   
       55 . A structure comprising a plurality of blocks comprising paired structural slabs and at least one spacer separating the paired slabs to form a void therebetween, wherein the voids of one or more blocks define at least one continuous cavity along at least two axes of the block for receiving at least one reinforcing member; and a reinforcing member received in the cavity.  
   
   
       56 . A method of assembling a structure, the method comprising the steps of: 
 arranging a plurality of blocks in a structure, the blocks comprising paired structural slabs and at least one spacer separating the paired slabs to form a void therebetween, such that the voids of one or more blocks define at least one continuous cavity along at least two axes of the block for receiving at least one reinforcing member; and    locating a reinforcing member within the continuous cavity to reinforce the structure.