Modular Building Construction System

Abstract

Disclosed herein is a modular building construction system for fabricating a facility. The system comprises a room module and a service network module. The service network module is arranged to support a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal. An outer surface of the room module is connectable to an outer surface of the service network module such that, when connected, the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

Description

TECHNICAL FIELD

The present invention relates to modular building construction systems for fabricating facilities.

BACKGROUND

The construction industry is known to have a chronically low level of productivity that has changed very little in the past seventy years. It is thought that the low level of productivity is a consequence of the generally accepted need for bespoke buildings to be developed for particular applications combined with ‘tried-and-tested’ construction methods.

Bespoke buildings typically take several years to design, construct and validate/qualify which is slow and by implication costly. Furthermore, building designs are also often subject to changes as a project progresses and, in some circumstances, buildings have to be further modified after completion in order to comply with a change in requirements, expansion or cost constraints.

The problem is particularly acute for research and medical facilities which often need to be constructed rapidly and which must be flexible to accommodate changes to their end use. For example, laboratory facilities such as vaccine development facilities, advanced therapy medicinal product facilities and cell and gene therapy facilities are often planned and then initiated very quickly, with a need for them to be constructed and commissioned in several months rather than several years and to be adaptable during and after construction.

In addition, once a building has been constructed, it is typically time consuming and costly to install service networks, such as ventilation systems, piping networks and electrical networks, in the building.

Modular building systems that aim to address certain disadvantages of conventional building techniques are known. For example, GB2602641A describes a system for installing a service network in a facility. Pre-assembled modules that are arranged to support conveying components of a service network such as electrical wiring and ventilation ducting are suspended from room ceilings and connected together to provide a service network.

Such systems have various advantages. They can simplify the installation of a service network in a facility because the pre-assembled modules can be manufactured off site and assembled in a modular fashion to fit out a particular facility. However, suspending the service network from the ceiling of rooms of the facility imposes certain constraints. It lowers the effective ceiling height of the rooms thereby reducing the space available for the rooms' primary function. It also imposes constraints on the services that can be routed. For example, the number and diameter of ventilation ducts that can be provided is limited by the space available. This can be problematic in certain applications, for example, where large volumes of fluid need to be moved through the service network such as medical facilities or manufacturing or scientific cleanrooms.

There is a need to provide modular building system that addresses some or all of the above-described disadvantages.

SUMMARY OF THE INVENTION

In accordance with a first aspect there is provided a modular building construction system for fabricating a facility. The system comprises a room module and a service network module. The service network module is arranged to support a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal. An outer surface of the room module is connectable to an outer surface of the service network module such that, when connected, the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

Optionally, the room module and the service network module are connectable such that, when connected, the service network module is located on top of the room module.

Optionally, an outer surface of the service network module is connectable to an outer surface of a further room module.

Optionally, when connected, the further room module is located on top of the service network module.

Optionally, the room module and service network module each comprise a frame.

Optionally, the plurality of conveying components are located inside the service network module frame.

Optionally, the outer surfaces of the room module and service network module are the respective surfaces of the room module and service network module frames.

Optionally, the room module and the service network module together define a first cell, and wherein the first cell is connectable to one or more further cells, each further cell comprising a room module connected to a service network module.

Optionally, when connected, the one or more further cells are located on top of the first cell or to the side of the first cell.

Optionally, at least one of the conveying components of the service network module is arranged to be connected to a corresponding conveying component of an adjacent service network module to provide at least part of a service network in the facility.

Optionally, the room module and the service network module frames have substantially the same length and width.

Optionally, at least one of the room module and the service network module has a length not greater than 16 m, a width not greater than 4.8 m and a height not greater than 4.2 m.

Optionally, the room module is a laboratory, manufacturing, medical treatment, office or corridor module.

Optionally, the service network module is provided with a plurality of pre-assembled modules which support the conveying components.

Optionally, the room module is provided with a ceiling vertically spaced from the top of the room module and a void between the ceiling and the top of the room module and wherein conveying components pass from the service network module through the void to the ceiling.

According to an aspect of the present invention there is provided a modular building construction system comprising a plurality of service network modules located parallel and adjacent to each other and a plurality of pre-assembled modules comprising conveying components are located within each service network module, wherein there is a corridor between the pre-assembled modules and a frame of the service network module.

Optionally, adjacent corridors of adjacent service network modules are adjoined to create a combined corridor such that, in use, access is provided to conveying components in pre-assembled modules on either side of the combined corridor.

Optionally, a lateral service corridor is provided perpendicularly to the corridors between the pre-assembled modules, the lateral service corridor joining up the combined corridors.

Optionally, the plurality of conveying components comprise at least one of ventilation ducting, electrical cable, electrical busbar, and fluid piping.

In accordance with a second aspect of the invention there is provided a facility comprising: a room module; and a service network module supporting a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal. An outer surface of the room module is connected to an outer surface of the service network module such that the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

Optionally, the facility further comprises a further room module connected to an outer surface of the service network module; and a further service network module connected to an outer surface of the further room module.

In accordance with a third aspect of the invention there is provided a service network module for a modular building construction system, the service network module arranged to support a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal, wherein an outer surface of the service network module is connectable to an outer surface of a room module such that, when connected, the service network module is located outside the room module thereby locating the conveying components of the service network outside the room module.

In accordance with a fourth aspect of the invention there is provided a method of assembling a facility comprising the steps: providing a room module and a service network module according to the first aspect; connecting an outer surface of the room module to an outer surface of the service network module such that the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

Certain embodiments of the invention provide a modular building construction system for fabricating a facility. The facility comprises one or more room modules, each room module having a service network module connected to it. The service network module contains conveying components that provide at least part of a service network.

The service network module is located outside (for example, on top of) the room module such that the service network is located outside the room module. Advantageously, locating the service network above the room module rather than running it through the room module increases the amount of space within the room module available for the room's primary purpose by increasing the effective ceiling height of the room module. This is particularly advantageous when the dimensions of modules are restricted, for example, to ensure modules can be transported by road on a conventional size trailer.

Advantageously, increasing the ceiling height of the room module can allow the room module to be used for additional applications where increased ceiling height is required, for example certain manufacturing applications.

Advantageously, locating the services in a separate module outside the room module can also increase the amount of space available for services. This means, for example, that a greater number of fluid ducts and/or fluid ducts having a larger diameter can be provided without compromising the amount of usable space within the room module. This can be particularly useful in certain applications where high volumes of fluid need to be moved, such as in cleanrooms.

Advantageously, the modules can be manufactured partly or fully off-site and easily and quickly assembled on-site to provide a facility.

In certain embodiments, a room module and associated service network module is arranged to be connected to one or more further room modules and service network modules to form a larger facility. The modules can be connected on top of or to the side of each other. In such embodiments, the services of adjacent service network modules can be connected to form a larger service network within the facility.

Various further features and aspects of the invention are defined in the claims.

Unless defined otherwise, all technical and scientific terms used herein have the meaning commonly understood by a person skilled in the art to which this invention belongs.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings where like parts are provided with corresponding reference numerals and in which:

FIG. 1A is a simplified diagram showing an exploded view of a facility fabricated using a modular building construction system in accordance with certain embodiments of the invention;

FIG. 1B is a simplified diagram of the facility of FIG. 1A assembled;

FIG. 2 is a simplified diagram showing a partially exploded view of a further facility fabricated using a modular building construction system in accordance with certain embodiments of the invention; and

FIG. 3 is a simplified diagram of a further facility fabricated using a modular building construction system in accordance with certain embodiments of the invention.

FIG. 4 is a schematic diagram showing an elevation view of a service network module located above a room module; and

FIG. 5 is a schematic drawing showing a plan view of a number of room modules in parallel with their associated service network modules each comprising pre-assembled modules.

DETAILED DESCRIPTION

FIG. 1A is a simplified diagram showing an exploded view of a facility fabricated using a modular building construction system in accordance with certain embodiments of the invention.

The facility 100 comprises a first room module 101, a first service network module 102, a second room module 103 and a second service network module 104. The second room module 103 and second service network module 104 substantially correspond with the first room module 101 and first service network module 102 respectively.

The first room module 101 comprises a first frame 105. The first frame 105 is a self-supporting frame that comprises a plurality of beams and uprights. The beams and uprights are spaced apart to form openings for receiving wall panels, ceiling panels, floor panels, doors and windows.

The first room module 101 can be, for example, a laboratory, manufacturing cleanroom, medical treatment, plant, office or corridor module.

The first service network module 102 is arranged to support conveying components that provide at least part of a service network in the facility 100.

The first service network module 102 comprises a second frame 106. The second frame 106 comprises a plurality of beams and uprights. The first service network module 102 is arranged to support a plurality of conveying components located inside the frame including first conveying component 109a, second conveying component 109b, third conveying component 109c and fourth conveying component 109d. It will be understood that the conveying components 109a 109b 109c 109d are depicted schematically in FIGS. 1A and 1B.

The conveying components are arranged to convey fluid, power and electrical signals through the facility 100. The conveying components can comprise, for example, ventilation ducting (air supply and extraction), electrical power cable, electrical signal cable, electrical busbar, or fluid supply and return piping.

The conveying components are contained within and supported by the second frame 106. In certain embodiments, the conveying components are secured directly to the second frame 106. Alternatively, or additionally, in certain embodiments, the conveying components are supported by one or more supports secured to the second frame 106 such as a cable tray for supporting electrical cable. Alternatively, or additionally, in certain embodiments, a plurality of pre-assembled modules can be secured to the second frame 106. The pre-assembled modules can comprise ventilation ducts, electrical cable trays, lighting connectors, room utilities and piping for delivery of fluids, particularly gases. The pre-assembled modules can be of a standard size and can be secured together to form a larger service network.

An outer surface 107 of the first frame 105 is connectable to an outer surface 108 of the second frame 106. When the first frame 105 and the second frame 106 are connected, the first service network module 102 is located on top of the first room module 101. In this way, the conveying components 109a 109b 109c 109d of the service network are located outside the first room module 101.

The first frame 105 and the second frame 106 can be connected in various suitable ways. For example, the outer surfaces 107108 can be brought into contact, and suitable fixings, such as bolts, can be passed through holes in the frames 105106 to secure them together.

The first room module 101 and first service network module 102 when connected together define a cell.

A further outer surface 110 of the second frame 106 is connectable to an outer surface of the second room module 103. When connected, the second room module 103 is located on top of the first service network module 102. The second room module 103 and the second service network module 104 are connectable in the same manner. In this way, a facility 100 that has several floors can be constructed by stacking room modules and service network modules on top of each other.

Typically, the modules are prefabricated in a factory and transported to site separately, for example by road haulage, before being assembled on site to form the facility 100.

The first frame 105 and second frame 106 have substantially the same width and length such that they occupy substantially the same footprint.

In certain embodiments, the first room module 101 and/or the first service network module 102 have a length of 16 metres (m) and a width of 4.8 metres (m). In certain embodiments, the first room module 101 and/or the first service network module 102 have a height of 4.2 metres (m). Advantageously, this can allow the modules to be transported using conventional road haulage.

The modular building construction system can be used for a range of applications including fabricating medical, research and manufacturing facilities, schools etc. For example, the modular building construction system can be used to construct vaccine development facilities, cell and gene therapy facilities and advanced therapy medicinal product facilities.

A method of assembling a facility will now be described with reference to FIG. 1B. FIG. 1B is a simplified diagram of the facility 100 of FIG. 1A assembled. In this example, the facility 100 has two floors and is made up of two room modules 101103 and two service network modules 102104. It will, however, be understood that different configurations of facility are possible by providing different numbers of modules and locating them relative to each other.

The method of assembling the facility 100 includes providing the room modules 101103 and the service network modules 102104. Typically, the modules have been pre-fabricated offsite. The facility 100 is assembled at the site where it will be used.

The first room module 101 is secured in place on the site. The first service network module 102 is positioned on top of the first room module 101 typically using a suitable crane. The first room module 101 and first service network module 102 are then secured together, for example by bolting their respective frames together. The process is repeated to secure the second room module 103 on top of the first service network module 102, and the second service network module 104 on top of the second room module 103.

Further modules can be secured above or alongside the first room module 101, first service network module 102, second room module 103, and second service network module 104 depending on the desired layout of the facility 100.

FIG. 2 is a simplified diagram showing a partially exploded view of a further facility fabricated using a modular building construction system in accordance with certain embodiments of the invention.

The facility 200 depicted in FIGS. 2 is composed of multiple cells including a first cell 201, a second cell 202, a third cell 203 and a fourth cell 204. Each cell comprises a room module and a service network module located above it.

The first cell 201 is located on the ground floor of the facility 200. The second cell 202 is located on top of the first cell 201 and is located on a first floor of the facility 200. The third cell 203 is located adjacent to the first cell 201 on the ground floor of the facility 200. The fourth cell 204 is located on top of the third cell 203 and adjacent to the second cell 202 and forms a first floor of the facility 200. The facility 200 includes further cells arranged and connected in a corresponding manner.

The facility 200 is assembled in a corresponding manner as described with reference to FIGS. 1A and 1B.

One or more of the room modules of the facility 200 can be a plant room module containing equipment for supporting other room modules. For example, each floor of the facility 200 can include at least one plant room module. In such embodiments, the service network modules across a floor can be connected such that services can be distributed across an entire floor or part of a floor.

FIG. 3 is a simplified diagram of a further facility fabricated using a modular building construction system in accordance with certain embodiments of the invention.

The facility 300 is a two-floor facility composed of multiple room modules and service network modules.

FIG. 4 is a schematic diagram showing an elevation view of a service network module 402 located above a room module 401 as part of a facility 400. The room module 401 comprises a first frame 405 and the service network module 402 comprises a second frame 406. The first frame 405 and the second frame 406 are self-supporting frames that each comprises a plurality of beams and uprights. The beams and uprights are spaced apart to form openings for receiving wall panels, ceiling panels, floor panels, doors and windows.

A number of pre-assembled modules 421 are located within the service network module 402 and secured to the second frame 406. The pre-assembled modules 421 support conveying components that provide at least part of a service network in the facility 400. The pre-assembled modules 421 can comprise ventilation ducts, electrical cable trays, lighting connectors, room utilities and piping for delivery of fluids, particularly gases. The pre-assembled modules 421 can be of a standard size and can be secured together to form a larger service network. FIG. 4 illustrates ventilation ducts 423 supported by pre-assembled modules 421. Ventilation supply ducts 425 and ventilation extract ducts 427 are attached to the ventilation duct 423 and pass vertically downward from it, out of the service network module into the room module. A ceiling 429 is provided in the room module 401 and the ventilation supply ducts 425 and ventilation extract ducts 427 terminate at that ceiling 429 at outlets 431 and inlets 433 respectively. The ceiling 429 is located at a distance beneath the top beam of the first frame 405 and a void 434 is created between the upper surface of the ceiling 429 and the top of the room module 401. The ventilation supply ducts 425 and the ventilation extract ducts 427 pass through that void 434.

FIG. 5 is a schematic drawing showing a plan view of a number of room modules 401 arranged adjacent to each other and parallel to each other with their associated service network modules 402 located on top, each comprising pre-assembled modules 421. A modular header 435 runs perpendicularly to the pre-assembled modules 421. A U-shaped service corridor 437 is located within the second frame 406 and surrounds each of the pre-assembled modules 421. Adjacent service corridors 437 create a combined corridor 439 which provides service access to the pre-assembled modules 421 on the left-hand side and the right-hand side of the combined corridor 439. A lateral service corridor 441 is created along the length of the service network modules 402 by their adjacent service corridors 437.

It will be understood that various configurations of facility can be provided using the described system. For example, in certain embodiments a facility with one floor, two floors or more than two floors can be provided. In certain embodiments, each floor can be composed of multiple room modules in various layouts depending on the intended use of the facility.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims are generally intended as “open” terms (e.g., the term “including” or “comprising” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, means at least two recitations, or two or more recitations).

It will be appreciated that various embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made without departing from the scope of the present disclosure. Accordingly, the various embodiments disclosed herein are not intended to be limiting, with the true scope being indicated by the following claims.

Claims

1. A modular building construction system for fabricating a facility comprising: a room module; anda service network module arranged to support a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal, whereinan outer surface of the room module is connectable to an outer surface of the service network module such that, when connected, the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

2. The modular building construction system according to claim 1, wherein the room module and the service network module are connectable such that, when connected, the service network module is located on top of the room module.

3. The modular building construction system according to claim 1, wherein an outer surface of the service network module is connectable to an outer surface of a further room module.

4. The modular building construction system according to claim 3, wherein when connected, the further room module is located on top of the service network module.

5. The modular building construction system according to claim 1, wherein the room module and service network module each comprise a frame.

6. The modular building construction system according to claim 5, wherein the plurality of conveying components are located inside the service network module frame.

7. The modular building construction system according to claim 5, wherein the outer surfaces of the room module and service network module are the respective surfaces of the room module and service network module frames.

8. The modular building construction system according to claim 1, wherein the room module and the service network module together define a first cell, and wherein the first cell is connectable to one or more further cells, each further cell comprising a room module connected to a service network module.

9. The modular building construction system according to claim 8, wherein, when connected, the one or more further cells are located on top of the first cell or to the side of the first cell.

10. The modular building construction system according to claim 1, wherein at least one of the conveying components of the service network module is arranged to be connected to a corresponding conveying component of an adjacent service network module to provide at least part of a service network in the facility.

11. The modular building construction system according to claim 1, wherein the service network module is provided with a plurality of pre-assembled modules which support the conveying components.

12. The modular building construction system according to claim 1, wherein the room module is provided with a ceiling vertically spaced from the top of the room module and a void between the ceiling and the top of the room module and wherein conveying components pass from the service network module through the void to the ceiling.

13. The modular building construction system according to claim 1 comprising a plurality of service network modules located parallel and adjacent to each other and a plurality of pre-assembled modules comprising conveying components are located within each service network module, wherein there is a corridor between the pre-assembled modules and a frame of the service network module.

14. The modular building construction system according to claim 13, wherein adjacent corridors of adjacent service network modules are adjoined to create a combined corridor such that, in use, access is provided to conveying components in pre-assembled modules on either side of the combined corridor.

15. The modular building construction system according to claim 14, wherein a lateral service corridor is provided perpendicularly to the corridors between the pre-assembled modules, the lateral service corridor joining up the combined corridors.

16. The modular building construction system according to claim 1, wherein the plurality of conveying components comprise at least one of ventilation ducting, electrical cable, electrical busbar, and fluid piping.

17. A facility comprising: a room module; anda service network module supporting a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal, whereinan outer surface of the room module is connected to an outer surface of the service network module such that the service network module is located outside the room module, thereby locating the conveying components of the service network outside the room module.

18. A facility according to claim 17, further comprising: a further room module connected to an outer surface of the service network module; anda further service network module connected to an outer surface of the further room module.

19. A service network module for a modular building construction system, the service network module arranged to support a plurality of conveying components that provide at least part of a service network in the facility, each conveying component arranged to convey at least one of a fluid, power and an electrical signal, wherein an outer surface of the service network module is connectable to an outer surface of a room module such that, when connected, the service network module is located outside the room module thereby locating the conveying components of the service network outside the room module.