Packing and Assembling Same

Field of the Invention

The present invention relates to prefabricated building modules, and more particularly, to volumetric prefabricated building modules. More specifically, although not limited thereto, the present invention relates to prefabricated building modules having expandable and/or retractable volumetric structures. This invention also relates to shipping containers for transporting volumetric prefabricated building modules. Furthermore, the present invention also relates to methods of contracting the prefabricated building modules at factory and/or expanding the contracted building modules at construction sites for subsequent assembly to form multi-storey buildings.

Background of the Invention

The use of prefabricated building modules for construction is advantageous. For example, building modules could be prefabricated at factories under factory scales and in factory conditions, and then delivered to a building site for expeditious on-site assembly. Prefabricated building modules are broadly classified into volumetric and non-volumetric types. A volumetric prefabricated building module is understood to persons skilled in the art as one which has a volume defined by a structured enclosure or boundary when ex-factory. This is in contrast to non-volumetric type in which panels and other prefabricated components are stacked or packed together with minimum space in-between. The use of volumetric prefabricated building modules in construction is particularly advantageous because a volumetric sub-assembly means even less works (and therefore less uncertainties) at site. For some construction sites, for examples, remote sites which are too primitive or too difficult to access, or where resources are prohibitive, or when weather conditions or environmental restrictions do not permit, construction using prefabricated modules are probably the only practical option.

However, the use of volumetric prefabricated building modules in buildings construction means a higher demand on logistics and freight capacity, as well as higher transportation costs, since volumetric building modules are typically not optimized for transport efficiency. In addition to the requirements for higher freight capacity and higher transportation costs, the transportation of volumetric building modules also lead to the requirements of additional shipping containers and additional packing materials which are not particularly friendly to the environment.

Therefore, it is desirable if improved volumetric prefabricated building modules and/or methods of shipping same which alleviate known shortcomings are available.

Summary of Invention

According to the present invention, there is provided a volumetric prefabricated building module configured as a shipping container for shipping transportation of a plurality of contracted volumetric prefabricated building modules and comprising crane engagement means for lifting by a crane, wherein the volumetric prefabricated building module is configured for storing the plurality of volumetric prefabricated building modules in a contracted state for shipping transportation. A volumetric prefabricated building module which is configured as a shipping container for shipping transportation of a plurality of contracted volumetric prefabricated building modules means is advantageous for at least saving an extra shipping container. This means less packing work and time, less packing materials, less transport cost, less shipping space, less unpacking, less waste, and more environmental friendly, especially when no return shipping of a rigid and bulky empty shipping container is required.

According also to the present invention, there is also provided a volumetric prefabricated building module comprising a steel structure which is expandable between a contracted volumetric state of a first module volume in a first locked configuration for shipping transportation, and an expanded volumetric state of a second module volume in a second locked configuration for on-site assembly.

A prefabricated building module which could be expandable and contractable between expandable and contractable volumetric states means the possibility of more efficient shipping while meeting the requirements of edge-coupled connection requirements for most practical building applications.

For example, the steel structure may be expandable and contractable between the first and second locked configurations vertically and/or laterally. This provides the flexibility to edge-couple with modules of different dimensions.

According to an aspect of the present invention, there is provided a set of volumetric prefabricated building modules comprising a first volumetric prefabricated building module described herein, and at least one second volumetric prefabricated building module described herein, wherein the first and second volumetric prefabricated building modules are adapted for interconnection in an edge-coupled manner or a flush relationship to form a structural sub-assembly. Construction using such a set of volumetric prefabricated building modules is advantageous because transport and construction efficiency could be enhanced.

According to another aspect of the present invention, there is provided a shipping container for shipping or transporting a set of volumetric prefabricated building modules which is configured to be structurally connected together for integration into a building sub-assembly or a building structure, wherein the container comprises a first volumetric prefabricated building module of the set of volumetric prefabricated building modules, the first volumetric prefabricated building module defining a storage volume for receiving at least one second volumetric prefabricated building module for transportation. A container which is in itself or comprises a first volumetric prefabricated building module for receiving another, or second, volumetric prefabricated building module means enhanced transportation efficiency since the two volumetric building modules could be transported together in synchronous while occupying the volume of a single container. In addition, this is more environmentally friendly and provides a more cost-efficient transport solution because there is no need to return the container to the container owner which usually a freight forwarder. Such a characteristic also enhances assembling efficiency since the more volumetric is a prefabricated building module, the less on site works are required.

The container may comprise a major side or a minor side which defines an access aperture through which the second volumetric prefabricated building module can move in and out of the container by lateral translation while in contact with the container floor during packing and unpacking.

A container which is arranged to permit a volumetric prefabricated building module contained therein to move into and out of the container through a major side or a minor side by lateral translation, for example, by sliding, means no heavy duty crane or other specialized equipment is required to move the bulky and heavy modules into position for sub-assembly with other components of the set of prefabricated building module.

The steel structure of a first volumetric prefabricated building module may be adapted for integration with a second volumetric prefabricated building module into the steel structure of a high-rise or multi-storey building in an edge-coupled manner. Steel structures are preferred in many building applications because of their resistance to earthquake damage and to lateral deformation.

Construction using prefabricated building modules in practice typically requires an ensemble of prefabricated building modules in an edge-coupled manner or in a flush relationship. However, modules which could be connected in such a manner typically means that they have to be transported separately. A prefabricated building module which could be shipped or transported within another prefabricated building module while being capable of edge-coupled connection with that another prefabricated building module is highly advantageous and makes construction using prefabricated building modules more attractive.

The steel structure may comprise a partitioning structure which partitions the storage volume into a plurality of storage compartments for receiving a corresponding plurality of second prefabricated building modules, and the partitioning structuring also defines the partitioning of the first prefabricated building module.

A container having a partitioning arrangement which is also the partitioning arrangement of the first volumetric prefabricated building module is advantageous so that useful partitioning of the building module could be prefabricated to minimize the need of works at site. The prefabrication of such partitioning arrangements is especially advantageous when the partitioning arrangement also forms an integral part of the weight-bearing structure of the first volumetric prefabricated building module which is designed to share the weight bearing of a multi-storey building. This also provides the flexibility of a more deformation resistant building structure.

According to a further aspect of the present invention, there is provided a method of packing a second volumetric prefabricated building module described herein into a container described herein, the method comprising assembling the second prefabricated building module into the first locked position, and laterally moving the second prefabricated building module into a storage compartment of the container while in contact with the container.

According to a further aspect of the present invention, there is provided a method of unpacking a second volumetric prefabricated building module described herein from a container described herein and re-assembling same, the method comprising, the method comprising:-

Sliding the second prefabricated building module out of the container laterally while in contact with the container, and - Re-assembling the second prefabricated building module with bracing members of the container as structural columns.

Such a convenient unpacking process means less workers and less equipment are required on site.

According to a further aspect of the present invention, there is provided a method of construction of a multi-storey building, the method comprising:-

Assembling a building module subassembly, the building module assembly comprising a structural assembly of a plurality of prefabricated building modules of any of the preceding Claims;

Integrating one building module sub-assembly on another building module sub-assembly using a plurality of structure integrators; wherein the structure integrators are also spacers between vertically adjacent sub-assemblies. This invention also provides a method of shipping volumetric prefabricated building modules using a shipping container, wherein a volumetric prefabricated building module is in itself configured as a shipping container.

In other aspect, the present invention describes a multi-storey or a high-rise building or building structure comprising a plurality of volumetric prefabricated building modules, and/or containers, and/or a set of volumetric prefabricated building modules described herein in stacked structural interconnection.

The spacers may be placed on top corners of the first prefabricated building modules for structurally integrating with corresponding corners of corresponding first prefabricated building modules.

In a further aspect, the present invention describes an apartment unit or a hotel room comprising a plurality of volumetric prefabricated building modules, and/or containers, and/or a set of volumetric prefabricated building modules as described herein.

Brief Description of Drawings

Exemplary embodiments illustrating the practice or realization of the present invention will be explained below by way of example with reference to the accompanying drawings, in which:-

Figure 1 is a perspective view schematically showing a multi-storey building comprising a plurality of volumetric prefabricated building modules according to embodiments of the present invention,

Figure 2 is a perspective view schematically showing a multi-story building of Figure 1 in construction, Figure 3 is a schematic plan view showing an apartment unit of Figure 2 constructed from an assembly of volumetric prefabricated building modules according to embodiments of the present invention,

Figures 3A & 3B are schematic plan views showing the component second and third volumetric prefabricated building modules of the apartment of Figure 3 respectively in an expanded second locked configuration and a contracted first locked configuration,

Figures 3C & 3D are schematic plan views showing the component second and third component volumetric prefabricated building modules in contracted first locked configuration and stored within the first volumetric prefabricated building module,

Figures 3E shows a first volumetric prefabricated building module exposing its steel structure,

Figure 4 is a perspective view depicting a first volumetric prefabricated building module and a plurality of second and third volumetric prefabricated building modules in an expanded second locked configuration according to an embodiment of the present invention and arranged in an array,

Figure 5 depicts a first volumetric prefabricated building module with the plurality of second and third prefabricated building modules in the contracted first locked configuration according to an embodiment of the present invention and arranged in an array,

Figure 6 shows a set of volumetric prefabricated building module of Figure 5 with the third prefabricated building modules stored within the second prefabricated building modules and, with the second prefabricated building modules ready to be moved inside the first prefabricated building module, Figure 7 shows the set of volumetric prefabricated building module of Figure 6 with the second and third prefabricated building modules stored within the first prefabricated building module,

Figures 8 & 8A are respectively a perspective view and a front view depicting a container according to an embodiment of the present invention, Figures 8B & 8C are perspective views of the container of Figures 8 & 8A with cladding sheets on a major front side removed, and revealing second and third volumetric prefabricated building modules contained therein respectively with and without bracing members mounted,

Figures 8D & 8E are respectively perspective and front elevation views depicting a steel frame structure of the container of Figures 8 & 8A respectively with and without bracing members mounted,

Figure 8D1 shows a side view of a minor side of the container structure of Figure 8D with a cross bracing structure,

Figures 9A-9J illustrate an exemplary process transforming a second prefabricated building module from a first locked configuration vertically along the columns into a transitional configuration,

Figures 10A-10D illustrates an exemplary process transforming the second prefabricated building module from the transition configuration of Figure 9J horizontally along the beams into the expanded second locked configuration, Figures 10E & 10F are schematic side views illustrating the second prefabricated building module respectively before and after the horizontal transformation illustrated in Figures 10A-10D,

Figures 11A-11 D are schematic side views illustrating the second prefabricated building module in the second locked configuration being mounted with partitioning or boundary materials;

Figures 12A & 12B schematically depict an exemplary structural integration between two vertically stacked first prefabricated building modules,

Figures 12C & 12D respectively show a steel frame of a first volumetric prefabricated building module revealing joiner plates after removal of bracing members, and an enlarged view showing the joiner plates,

Figures 12E & 12F depict stacked integration of a plurality of first volumetric prefabricated building module integrated with joiner plates,

Figures 13A -13D schematically depict an exemplary structural integration of a plurality of prefabricated building modules both vertically and laterally,

Figures 14A -14D schematically depict an exemplary process of integrating the prefabricated building modules laterally,

Figure 15A schematically depicts an exemplary process of further integrating the prefabricated building modules vertically after the process of Figures 14A-14D, Figure 15B schematically depicts a structural assembly after the process of

Figure 15 with the floors omitted,

Figure 16 schematically a second exemplary embodiment showing a plurality of hotel rooms assembled from a plurality of prefabricated building modules of the present invention, and Figures 16A to 16D schematically illustrate a sequence of process for storing and retrieving the component prefabricated building modules from a first prefabricated building module. Detailed Description of Embodiments

A multi-storey building 10 depicted in Figure 1 comprises a multi-storey structure having a plurality of exemplary apartment units 20 on each storey. Each apartment unit, as depicted in Figure 2, is a structural sub-assembly constructed from a first module 100 of a first type of prefabricated building module, three second modules 200 of a second type of prefabricated building modules, and three third modules 300 of the third type of prefabricated building modules. Each of the first, second and third types of prefabricated modules is in itself a volumetric prefabricated building module which is pre-assembled at a factory and then transported to a building site for in-situ assembly at the building site.

A volumetric building module in the present context means a building module having a definite volume defined by boundaries, such as sidewalls, ceiling, floor and partitions, of the building module in a fixation state. The volumetric prefabricated building modules are typically transported from a factory to a building site, and then assembled at the building site in a manner to be illustrated in more detail below.

Referring to Figures 3 to 3E, 8 to 8E, 12A to 12F, the first volumetric prefabricated building module (the "first module", or the "main module") 100 packed as a shipping container 400 is substantially rectangular and comprises a steel structure which defines a major sidewall 102, a major side surface 104, a floor 106, a ceiling 108, a first minor sidewall 110, a second minor sidewall 112, and two partitioning walls 114, 116. The floor, the ceiling and the two minor sidewalls all extend orthogonally from the major sidewall, and the boundary members collectively define the internal volume and compartments of the first module 100. The major sidewall extends along the major or longitudinal axis (Χ-Χ') of the module and defines the length of the module. The two minor sidewalls are respectively at the longitudinal ends of the major sidewall and extend laterally along the minor or transverse axis (Υ-Υ') of the module to define the depth of the module. The height of the module is defined by the separation or vertical clearance between the ceiling and the floor, which are connected to the sidewalls at their vertical extremities. It will be noted that the minor or transverse axis (Υ-Υ') is substantially orthogonal to the longitudinal axis (Χ-Χ').

The packing materials 410 of the container are corrugated metal cladding sheets which are designed for re-use as site hoardings to maximize utilization of packing materials.

As shown in Figures 3E & 8E, the major sidewall 102 comprises a steel grid of a major side frame which includes a pair of spaced apart and longitudinally extending steel beams, including an upper beam122 and a lower beam 124, that are structurally connected with a plurality of vertical columns 126a-d. The upper and lower ends of each vertical column 126a-d are mounted respectively to the upper and lower beams, thus forming a rectangular load bearing structural grid comprising a major side frame of the beams 122 and 124 and the lateral columns 126a and 126d. The major side frame is supported by the laterally spaced columns 126b&c which provide distributed support to the beams122, 124 along their length.

The ceiling 108 comprises a ceiling grid which is defined by an interconnection of beams comprising a pair of longitudinally extending steel beams 122 & 128 and a plurality of laterally extending beams 130a-d. The beams 122, 128 & 130a-d collectively form a substantially rectangular ceiling frame which defines the boundary of a main ceiling frame and comprises longitudinally extending beams 122 & 128 and lateral beams 130a & d. The lateral beams, which extend along the direction of the minor axis Y-Y', are connected to beams 122 & 128, which extend along the direction of the longitudinal axis X-X', at their respective longitudinal ends. Additional lateral beams 130 b, c are also connected to the main ceiling frame at locations corresponding to that of columns 126 b, c and in connection with the columns. In addition, a plurality of longitudinally extending beams 128 a-c is distributedly connected to the lateral beams 130a-d of the main ceiling frame at regular lateral space intervals along the length of the beams. Furthermore, two of the beams 128 a, c are arranged such that crane engagement fittings 120 are connected to their longitudinal ends to provide a horizontal stabilizing structure during crane lifting of the first module. The weight bearing structure for the container part of the first module will be explained further below.

Similar to the ceiling, the floor comprises a floor grid of steel beams which is connected to the major sidewall, albeit to the lower beam 124 instead of upper beam 122. The structure of the floor grid is structurally identical to that of the ceiling and the description above in relation to the ceiling structure would therefore apply mutatis mutandis. For example, reference to beams 122 and 128 should be changed to beams 124 and 132 respectively. The floor is further covered with a piece of concrete slab to provide a solid feel for human inhabitants.

The major side 104 comprises a major side grid which is defined by an interconnection of beams and columns comprising a pair of longitudinally extending steel beams 128, 132 and a plurality of columns 134 a-d. The major side grid is substantially identical to that of the major side frame of the major sidewall, although the major side of the first module is arranged to define lateral access to the internal compartments of the first module while the major sidewall is adapted to partition or block the internal volume from outside of the first module.

The first minor sidewall 110 extends laterally between the major side and the major side wall and is defined by a grid of steel structure comprising columns 126a, 134a respectively of the major side and major sidewall, beams 130a, 136a respectively of the ceiling and floor, and vertical stays 138a, 138b interconnecting beams 130a and 136a. The first sidewall further includes a diagonal strut 140 which extends diagonally across to provide addition resistance against lateral deformation of the first sidewall in the lateral direction, i.e., the direction of the minor axis Y-Y'. While the term "long beam" is used herein, it should be appreciated that the use is only a shorthand reference and a long team could be constructed from a plurality of component beams without loss of generality.

The second sidewall 112 and the partitioning structures 114 and 116 also extend laterally between the major side and the major side wall and each has a substantially identical grid structure as that of the first sidewall, although the second sidewall is connected to the other longitudinal end of the long beams 122 & 124, while the partitioning structures 114 and 116 are distributed along the length and respectively connected to the columns 126 c & b.

Each of the sidewall or partitioning structure is mounted with partitioning materials such as wall panels or partitioning panels which provide weather, thermal, fire or sound insulation where appropriate and without loss of generality.

Apart from the general grid structure described above, the first minor sidewall includes additional vertical stays 138a and 138b which are distributed along the length of the beams 130a and 136a and interconnect beams 130a and 136a, respectively of the ceiling and the floor at locations of the crane engagement fittings 120. The second sidewall also has the same further vertical stays which are connected in the same manner. The vertical stays, in combination with the carne engagement fittings and the long stays 128a, c, collectively define a weight bearing grid structure off the shipping container.

To facilitate structural coupling with other building modules or for integration into a building structure, a plurality of through bores is distributed on various edges of the steel frame. In addition, a plurality of joiner plates 420, which is used for holding bracing members 226, 326 when the first module is configured as a shipping container, is also used as integrators joining adjacent longitudinal beams of the first modules to be explained below.

A plurality of crane engagement fittings 120, as examples of crane engagement means, is mounted on the lateral ends of the ceiling frame. The crane engagement fittings are adapted for releasable engagement for lifting by a crane during transportation or when the main module is lifted into an assembly position. In the arrangement of Figure 8, the crane engagement means are distributed at longitudinal and lateral separations which are identical to that on standard 20-ft or 40-ft shipping containers

The second prefabricated building module (the "second module")200 is substantially rectangular and comprises a steel structure which defines a set of boundary frames comprising a first side 202, a second side 204, a floor 206, a ceiling 208, a first sidewall 210, a second minor sidewall 212. The boundary members collectively define the internal or compartment volume of this second module.

Similar to the main module, each of the various boundary frames of the second module comprises a plurality of steel beams and columns, and the collection of beams and columns define a complete module grid structure having a plurality of interconnected steel grids with common beams and columns. The steel structure of the second module is adapted for structural integration with that of the first module in an edge-coupled member so that adjacent corresponding side surfaces surrounding compartments formed on the first and second modules are in flush relationship. More specifically, internally facing surfaces of the floor 206 and ceiling 208 of the second module are respectively flush with corresponding internally facing surfaces of the floor 106 and ceiling 108 of the first module, while internally side surfaces of the sidewalls 210 and 212 of the second module are flush respectively with the corresponding internally facing side surfaces of the sidewall 110 and partitioning wall 116 of the first module. The floor 206, the ceiling 208, and the sidewalls 210, 212 of the second module also define a compartment having a first aperture on the first side and a second aperture on the second side which is opposite to the first side. The first aperture is adapted for forming a continuous and enlarged internal compartment when connected with the compartment defined by walls 110 and 116 of the first module with the first and second modules structurally connected with corresponding edges coupled and fastened.

In a modified embodiment of the first module as depicted in Future 8D1 , each or a selection of the sidewalls 110, 112, 114, 116 comprises a cross pair of diagonal struts 140 and 140a for even better lateral deformation resistance.

The apartment unit 20 includes another second module 200a which is structurally connected or integrated to both the first module 100 and the second module 200 described above to form a substantially rectangular plan portion. This second module is also adapted for connection with the other modules in flush relationship. Therefore, the steel structure on each of the side walls 212 and 212a (see Figure 3 and 3A) would have about a half-thickness of that of the partitioning structure 116.

This another second module 200a is a variation embodiment of the basic second module 200 in that a transverse partitioning wall 202a is formed on the side 202 to divide the compartments of the first and second modules. The major difference of this variation second module 200a is that its both sidewall structures are of half the thickness of the partitioning structure 116 of the first module. As an alternative, the partitioning wall 202a of the variation second module 202a could be removed when so desired without loss of generality.

The yet another second module 200b is structurally identical to the basic second module, although the sidewalls 210, 212 swapped sides.

In order to facilitate flush connection between the sidewalls of a second module and corresponding lateral partitioning structures of the first module, while at the same time permitting storage of the second module within a compartment of the first module as defined by the lateral partitioning structures, each of the floor and ceiling frames of the second module comprises a rigid steel frame which is expanded between an expanded state and a contracted state as illustrated in Figures 3A, 3B and 3D with more detailed description in the methods of expansion and contraction at Figures 9A to 11 D. Specifically, the ceiling comprises lateral or transverse beams 222, 228 and longitudinal beams 230a, 230b which collectively define a ceiling grid on which a plurality of beams 238 is mounted. The beams are arranged such that an extension structure comprising the lateral beam 228 is moveable on tracks formed on the longitudinal beams 230a and 230b between the contracted and expanded state. Specifically, each of the longitudinal beams 230a and 230b has a length less than that of the length of the corresponding receiving compartment of the first module and comprises an internal track. The extension structure comprises the beam 228 and end members 240 extending orthogonally from the ends of the beam 228. The end members are elongate and are slidably fitted on the tracks of the beams 230a, 230b so that the extension structure is moveable between an expanded position for flush connection with the first module and a contracted position for storage within the compartment. Fastening means are distributedly provided on corresponding parts on the end members and beams 230a and 230b so that the moveable parts could be released for moving upon loosening of the fastening means and locked to stay in a desirable state when re-configurable is completed. When the extension structure is in the expanded position as shown in Figure 9A, a cornered recess is formed at the external junction between the lateral beam 228 and the longitudinal beam 230a. This cornered recess is adapted for fittingly receiving a column 226a to complete the structural integrity of the second module in the expanded state to be explained below. Another extension structure comprising beam 222 and end members are slidably mounted on the opposite end of beam 228. As depicted in the enlarged view of Figure 9B, studs and bores are distributedly provided on the recess for integration the column with the ceiling or floor frame. The pair of extension structure provides a good degree of flexibility for expansion of the second module. Of course, where a lesser degree of extension is required, only one extension structure may be provided, with the other extension structure replaced by fixed beams without loss of generality.

The third module 300 is structurally similar to that of the second modules 200, and is adapted for edge-coupled flush connection with the second module 200. The main difference between the second and third modules is that the third module is more expandable than the second module. Similar to the second module 200, the internal sidewall of the third module is of a half-thickness compared to that of the partitioning wall 116 of the first module for the same reasons. Likewise, the apartment includes another third module 300a which is structurally connected to both the variation second module 200a and the third module 300. This another variation third module 300a is structurally identical to the third module 300, with the thickness of the internal wall 312, 312a being half of that of the boundary sidewalls 310,314. Extension structures similar to that of the second module are also present in the third module, and the description of such extension structures applies mutatis mutandis.

As shown in Figures 3B-3D and Figures 4-7, each of the second modules 200a, b, c could be contracted from the expanded state and stored into a corresponding storage compartment of the first module 100, and each of the third modules 300a, b could be contracted from the expanded state and stored into a corresponding contracted second module 200, and 200a. When the second and third modules are stored within the first module, a set of volumetric prefabricated building modules are contained within the first module which also functions as a main container to be described below. In the present context, the term "expanded state" refers to a volumetric state when the second and third modules are ready for flush or edged-coupled connection with the first module.

The main difference between the various types of modules is that the internal compartment or internal volume of the third type of modules is typically pre-installed with bulky utilities such as bath tub, water closets, shower stand, sinks etc, while that of the first and second type of modules is primarily configured as a storage compartment.

As shown in Figures 8 to 8C, the first module containing second and third modules is configured as a filled shipping container 400 with metallic hoardings mounted on the outer periphery to protect the exterior of the first module. The hoardings are mounted such that the carne engagement fittings remain exposed for crane engaged lifting operations. The contents of the filled container substantially comprise the packed volumetric prefabricated building modules as depicted in Figures 3D and 7, with the first module forming a major, if not the entire, portion of the weight bearing structure of the container.

To facilitate transport of the set of prefabricated modules in an efficient manner, it is advantageous that the second and third modules are contractable for storage within the first module and expandable for structural coupling with the first module in edge-coupled manner. On the other hand, it is desirable that load bearing columns of a prefabricated building module are rigid and with no significant longitudinal deformation when subject to a longitudinally applied compressive force. This competing requirement is resolved by having the columns mounted on the major side of the container as bracing members. The bracing members are arranged to provide reinforced structural support to the steel structure of the container during transportation while utilizing otherwise unused space on the container. To facilitate efficient transport of volumetric prefabricated building modules, it is advantageous that each of the second and third modules comprises a steel structure which is expandable between a contracted volumetric state of a first module volume in a first locked configuration for shipping transportation, and an expanded volumetric state of a second module volume in a second locked configuration for on-site assembly.

The transition from a contracted volumetric state to an expanded state can be divided into two major phases to be described in more detail below. The first stage comprises vertical expansion from a vertically contracted state to a vertically expanded state as shown in Figures 9-9J. Figure 9A shows a bare cage of the second module 200 in its fully contracted volumetric state in which the ceiling frame comprising a plurality of beams is supported by a plurality of stays extending from a floor frame. The second module in this contracted state is substantially a hallow cage maintained in shape by the plurality of stays interconnecting the ceiling frame and floor frame. As the columns 226a of the second module were removed before packing into the first module, it is now necessary to re-instate the columns back onto the bare cage of the second module. Firstly, the columns are attached to the cornered recesses on corresponding corners on the ceiling and floor frame. The recesses are shaped so that when a column is duly attached to the recesses, the outer surfaces of the column are flush with the outer surfaces of the adjacent beams. As shown in more detail in Figure 9B, each of the recess at the corner of the ceiling or floor frame comprises a plurality of positioning studs and through holes so that the columns could be readily fitted onto the correct positions and then fastened to reinforce the structure of the second module by restoring the load bearing columns.

After the load bearing columns have been re-stated onto the cage, a plurality of horizontal temporary stays 242 are attached to the upper ends of the columns so that a overall shape and configuration of the cage could be maintained during the vertical transformation process to be explained bellows. After the horizontal stays have been fastened to the columns, the fastening between the ceiling frame and the columns are loosen so that the ceiling frame can be moved vertically upward into a vertically expanded state. At this juncture, the plurality of stays operate to maintain a column network along which the ceiling frame could be moved. As an example, the ceiling frame is moved along the direction of the columns while maintaining a parallel orientation to the plain of the floor by use of a plurality of hydraulic jacks installed at each corner of the column formed cage. In addition to maintain the structural integrity of the cage during movement of the ceiling frame while the ceiling frame is no longer fastened to the columns, the horizontal stays also operate to limit the vertical range of movement of the ceiling frame so that it does not exceed a pre-determined vertical limit as defined by the bottom side of the stays. The ceiling frame is again fastened to the top ends of the columns when the pre-determined vertical limit has been reached due to blocking by the horizontal stays.

Figure 9I and 9J schematically show the relative position between the ceiling frame and the columns before and after the vertical transformation. After the vertical transformation has been completed, the second module will undergo a stage two horizontal expansion into the fully expanded state. After the vertical transformation of the second module has been completed, the structural grid of the second module is intact with the columns 226 supporting the ceiling frame. The plurality of hydraulic jacks are then repositioned onto the ceiling and floor frames, and oriented to push the sidewall structure comprising the beam 228 away from the beam 222 along the beams 230a, 230b. The specific depositions of the hydraulic are shown in more detail in Figure 10B. After the sidewall comprising the beam 228 has been moved into its fully expanded state, the elongate end members on the beam 228 are then fastened to adjacent beams 230a and 230b to lock the second module in the second locked configuration corresponding to the fully expanded state. The hydraulic jacks are then removed from the second modules. In undergoing this stage two horizontal transformation, the second module will move from the contracted transitional state of Figure 10E to the fully expanded state of Figure 10F. Furthermore, after the second module has been expanded into its fully expanded state and the hydraulic jacks removed, partitioning panels, walls or external walls are mounted onto the side frames of the second module to complete the second module. To expedite this panel fixing process, studs and apparatus are respectively provided on the underside of the panels and upper side of the floor frames for fast fitting. Furthermore, to facilitate easy reconfiguration of the second module, a detachable smallest side panel as shown in detail H of Figures 11C and 11 D, i) provided to provide easy access to loosen the fastening between the extension structure and the beams 230a & 230b.

Turning next to the vertical integration of a plurality of first modules into a high- rise structure with reference to Figures 12A to 13D. In order to construct a multi-storey building structure comprising a plurality of vertically stacked first modules, the first modules are stacked with corresponding longitudinal and lateral beams aligned as shown in Figure 12A. When a first module is stacked on top of another first module and aligned, the crane engagement fittings are spaced apart from each other without causing unevenness. This is achieved by providing a vertical integrator which also serves as a spacer between two corresponding vertical columns of vertically adjacent first modules and then integrating the corresponding columns by means of fastening means such as threaded nuts and bolts, the details of which are shown more particularly in Figure 12B.

When vertically integrating a plurality of first modules in a stacked relationship, the joiner plates 420 which are used to hold the bracing members during shipping are now converted to be used as vertical integrators. In use, the joiner plates 420 are turned to protrude away from the corresponding longitudinal beams, as shown in Figures 12D-12F. The turned joiner plates are then used to fasten adjacently stacked first modules to provide a more robust structure with additional distributed interlocking between modules.

In addition to vertical integration, the present a set of modules, includes first, second and third modules, is also adapted for horizontal or lateral integration so that the floor area of the high-rise building to be constructed could be adjusted as desired. As shown in Figure 13A, a single vertical integrator or spacer is shared between laterally adjacent modules for efficient assembly. As shown in Figure 13B, modules are laterally integrated by a plurality of fastening means distributed on the sides or edges of the relevant modules. As a result of the modular assembly, the building structure comprises dual beams and dual columns which are particularly desirable for high-rise structure stability.

Figures 14A - 15B illustrate schematically details of connection between the various modules either vertically and/or horizontally.

In another embodiment of this invention, a variation of the volumetric prefabricated building modules will be described. In this embodiment, the set of the volumetric prefabricated building modules comprises a first module 1100, a plurality of second module 1200 and a plurality of third module 1300. The first module 1100 is different from the first module of the previous embodiments in that each partitioned compartment of the first module 1100 is a compartment of a hotel room unit such that each first module comprises three hotel room units, a hotel room is thereby used as an example. Figures 16A to 16D illustrate the packing and unpacking of the various modules into the first hotel unit module 1100. The process is substantially the same as herein before described and will not be repeated here.

While the present invention has been explained with reference to exemplary embodiments described above, it will be appreciated that the embodiments are only non-limiting examples which are provided to help illustrate implementation of the invention. It will be appreciated to persons skilled in the art that the invention could be practiced through other embodiments or implementation means.

For example, while the embodiments have been described with reference to a first volumetric prefabricated building module which is rigid and not expandable, it will be appreciated by persons skilled in-the-art that this first volumetric prefabricated building could be expandable or contractible similar to the structure of the second or the third types without loss of generality.

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