This invention relates to accommodation modules for forming, with a multiplicity of such units, a single or multi-storey building each storey of which may comprise one or more parallel rows of modules arranged side by side with a corridor between adjacent rows.

This invention provides an accommodation module comprising a frame supporting sheet metal panels providing floor, ceiling, and side walls, the panels constituting the side walls of the module being formed with external vertically extending ribs which are of dovetail cross-section and tie members having dovetail shaped sockets to receive and lock on the ribs of the side walls to span between side walls of adjacent modules and to support the side walls against separation during casting of a concrete partition between the walls.

The invention also provides an accommodation module having a frame, side wall, ceiling and floor and an inner smaller module comprising a frame having side walls, ceiling and a floor mounted within the first mentioned module to create a separate room within the module.

The following is a description of some specific embodiments of the invention, reference being made to the accompanying drawings in which:

Figure l is a perspective view of an accommodation module in accordance with the invention;

Figure 2 is a perspective view looking down on a corner of the nodule of Figure 1;

Figure 3 is a plan view of the corner shown in Figure 2;

Figure 4 is a perspective view of the joint between a lower pair of modules and an upper pair of modules;

Figure 5 is a detailed view in perspective of a tie between facing walls of an adjacent pair of modules;

Figure 6 is a vertical section through a pair of modules illustrating the tie between the modules;

Figures 7 and 8 show alternative forms of ties;

Figure 9 is a vertical section through the joints between upper and lower pairs of modules;

Figure 10 shows an alternative form of profiled sheet and a further form of tie extending between the sheets;

Figure 11 comprises a number of illustration of a ^■ 'dry" lining for the interior of the module;

Figure 12 comprises a number of illustrations of a method of wet lining walls of the module;

Figure 13 is a detailed sectional view through one wall of the module showing the lining arrangement;

Figure 14 illustrates arrangements for securing

connectors to the wall of the module of Figure 12;

Figure 15 is a perspective view of the detailed construction of the floor of one module and ceiling of an adjacent module;

Figure 16 illustrates details of the casting of a concrete layer over the ceiling of the module;

Figure 17 illustrates details of an inner module erected within the module erected in one corner of the module z provide a room within the module; and

Figure 18 illustrates arrangements for transporting the basic module.

Referring firstly to Figure l of the drawings, there is shown a lightweight accommodation module which is intended to form an accommodation block with a multiplicity of such modules. The block may be erected on a pre-formed foundation and may be in the form of a multi-story building each storey comprising parallel rows of modules with a communications corridor between the adjacent rows. Alternatively one or more storeys of modules can be erected on a floor or roof of an existing building such as a multi-storey carpark which can then be adapted to provide both accommodation units and car-parking facilities.

The module 10 illustrated in Figure 1 of the drawings is a generally lightweight boxed shaped form having one end external end 11 fitted with a window unit and one internal end 12 adapted to open onto a central corridor between rows of modules. The module

comprises a frame having steel corner posts 13 inter-connected by steel, angle section upper and lower longitudinal members 21, 22. At the external end of the module the posts 20 are interconnected by upper and lower angle cross-members 23, 24 and at the corridor end 12 of the module the posts are interconnected at the top of the module by a deep pressed steel lintel 14 and at the bottom of module by by a heavy angle section 15.

The module has side walls 25 formed from lightweight steel sheeting have external vertically extending dovetail section ribs 26 at closely spaced locations along each sheet and with pairs of raised arcuate cross-section ribs 27 spaced between each pair of ribs 26. The sheets 25 are secured to the longitudinal members 21, 22 and the corner posts by means of self piercing rivets indicated at 28. Similar sheets 29 are provided at the ends of the module. By way of example, the sheets may be of the type sold under the name "Alpharib".

The ceiling 30 of the unit is formed by a further panel of lightweight steel sheeting having a series of inverted cross-sections 31 in cros-section the base of each of which is formed with a dovetail section raised rib 32. The ceiling panel sheet 30 is secured to the upper longitudinal members 21 and cross-members 23 by self-piercing rivets 34.

Each corner post 20 is made up of two channel section members 35, 36 rivetted together with the side of one channel 36 against the back of the other channel 35. The channel 35 is secured to the longitudinal members 21 and 23 by rivets and the channel 36 is secured to the transverse members 23,

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24 by similar rivets. The ends of the walls 25 and 29 have out turned flanges 37, 38 which are rivetted to the adjacent side walls of the channels.

The channel 35 of the corner post secured to the longitudinal members of the module projects above the longitudinal members by a short distance and has a cup plate 39 welded thereto to receive a corresponding plate 40 at the foot of the post of the module above. The plate 39 has a deep arcuate recess opening into the channel for a purpose described later.

Figure 4 of the drawings illustrates the connection between the lower and an upper pair of modules with a corridor to one side of the sets of modules. The plates 39 at the lower ends of the posts of the upper modules are secured to the corresponding plates 46 at the upper ends of the posts of the lower modules by high strength bolts with a fish plate 45 sandwiched between the upper and lower plates to which a horizontally extending inverted T section beam 46 is secured to extend across the corridor and to be coupled in the joints an upper and lower pair of modules on the other side of the corridor in a similar way. The beams 46 support pre-cast concrete planks 47 to provide the floor for the corridor.

As can been seen in Figure 4, an adjacent pair of modules is located with the side wall 25 of modules closely spaced from other another. The upper ends of the open dovetail section ribs 26 on the side walls and the ends of the troughs 31 on the top wall are block off with a high-duty EPDM filler or other similar foamed plastics filler and concrete is cast

between the side walls of the accommodation units with temporary shuttering at the ends of the units to form concrete walls between the units in which the dovetail section ribs are firmly embedded so that the sheet steel walls of the units formed a composite structure with the concrete.

To prevent the walls from deflecting under the load of the liquid concrete when it is poured between the walls, the walls are interconnected at least towards the lower ends thereof by tie members as illustrated in Figure 5. Each tie member comprise a twisted steel bar 50 formed with dovetail sections slots 51 at either end to embrace and lock with the dovetail section ribs 26 on opposing side wails. At least one of the ribs may be formed with a projecting stud 51 to define the height at which the tie member is to locate. By way of example, the tie members may be located one third of the way up from the bottom of the pair of modules. One tie member only may be provided between each opposing pair of ribs or several tie members may be provided at different heights between the ribs. The tie member 50 illustrated in Figure 5 has a single twist indicated at 50 at its centre. The tie member illustrated in Figure 6 has two twists 53 in its central region to stiffen the tie member.

Figure 7 shows an alternative form of tie member in which a flat strip 55 is provided with dovetail section slots 56 at each end and with intermediate wholes 57.

Figure 8 shows further form of tie member in which two pairs of shaped jaws 60 are provided to embrace the dovetail section ribs and the pairs of

jaws are secured together by a bolt 61 with slots being provided in the jaws to allow the separation of the jaw members to be adjusted as required.

Figure 9 of the drawings illustrates the section through the joint between four segments include a dense concrete wall between adjacent segments with steel reinforcement indicated at 65 at the joint. A covering layer of lightweight or dense concrete 66 is cast on the roof panels of the modules. Alternatively pre-cast concrete panels formed, for example, of a concrete known as "GASCON" could be used to form the module rooves in which case the metal panels 30 may be omitted and the concrete panels are then laid directly onto module frame members 21, 23 and 14. Figure 9 also illustrates the compressible seals 67 which are located between the underside of the floors of the upper modules and the cast concrete roof 66 of the lower modules to prevent the concrete cast being between the side walls of the modules from entering the gaps between the floors and ceilings of the modules.

Figure 10 shows an alternative form of profile for the side walls of the module which is of similar form to that of the ceiling described previously and includes a raised dovetail section rib 70. In this case the tie member extending between the side walls comprises shaped jaws 71 mounted upon a screw threaded stud 72. The studs of the respective screw threads are oppositely handed and are coupled by an internally screw threaded sleeve 73 to adjust the separation of the jaws 71 as required.

Figures 11A to 11G illustrate the dry lining system for the internal surfaces of the accommodation

module using conventional plaster-board or the like materials.

Figures 12A to 12E illustrate a system for wet lining the walls of the accommodation unit. Each wall to be lined is laid horizontally prior to erection with its room side uppermost as illustrated in Figure 12b. An open weave glass fibre cloth is then glued to the profiled steel sheeting and a "self-levelling" gypsum based screed is then laid one the wall and levelled as illustrated in Figure 12E. 3y way of example, the screed may be formed from a material supplied by KNAUF under the designation F325. This is a pre-mixed powder compound based on special cements ready to mix with water and containing fine particle fillers and a combination of organic spreading and binding agents. When the gypsum screed has set, the walls are erected to create the accommodation module. Figure 13 illustrates the screeded wall of an accommodation module as erected in a building.

Where fixings are required in the accommodation module on the side walls, the dovetail cross-section recesses on the inner faces of the side-walls of the unit may be utilised to receive "LINDAPTER" type fastening devices as illustrated at 80 on Figures 14A and 14B.

Figure 15 illustrates parts of the joints between upper and lower modules including the cast concrete layer 85 extending over the top wall 31 of the module. As illustrated in Figures 16A and 16B, the weight of the concrete can be temporary supported during the casting operation by means of clips 90 secured to the upstanding dovetail section ribs 32 on

the ceiling panel and connected by wires 91 to a steel beam 92 extending the length of the combination module between cross-members 93 resting on the transverse members 23 of the frame of the module.

Figure 16C illustrates details of the shuttering for the perimeter of the ceiling panel for the casting operation.

Figures 17A to 17G illustrate details of an inner smaller free-standing module which is erected within the main module at a corner thereof to provide a separate room such as a bathroom. The construction of the inner module again comprises a frame supporting lightweight steel panels, both panels of the inner module which are to engage in the corner of the outer module being formed with out-turned flanges 100. On the side wall, the flanges 100 are arranged to locate in the dovetail section recesses formed by the dovetail section rib 26 of the outer panel.

The ribs of the other wall of the inner module locate against inwardly projecting dove tail section ribs on the wall.

Figures 18a and 18b illustrate arrangements for reinforcing the ends of the erected accommodation unit for transport and which are removed on site prior to erection of the module.