Connector for a modular building

Abstract

A connector for a modular building or building module is disclosed, the connector comprising: a base comprising a top plate and a bottom plate connected by a plurality of walls, the top plate defining a drainage aperture; an alignment portion connected to and extending from the top plate for connection to a first column of the building to align the first column with the base, wherein the alignment portion is spaced away from the bottom plate; wherein the alignment portion comprises a first alignment plate and a second alignment plate each connected to and extending from the top plate to form an interior angle between the first and second alignment plates; wherein the interior angle faces the drainage aperture.

Description

"Connector for a modular building"Technical Field

[0001] The present disclosure relates to a connector for use in a modular building, and modules or subcomponents of the modular building assembled with the connector.Background

[0002] The construction of new buildings can be a time consuming process. During construction of a new building, access to and around the building site is restricted for safety reasons. This can cause inconvenience, as well as noise and dust pollution, for the occupants of nearby buildings.

[0003] In some circumstances, entire buildings can be assembled offsite, or formed as modules or subcomponents which can be connected or assembled on site. This reduces the amount of time spent assembling the building on the building site, and may lead to the new building being completed sooner.

[0004] The assembly of the subcomponents or the modules may be achieved by providing connectors which facilitate the assembly process.

[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

[0006] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.Summary

[0007] Some embodiments relate to a connector for a modular building or building module, the connector comprising: a base comprising a top plate and a bottom plate connected by a plurality of walls, the top plate defining a drainage aperture; an alignment portion connected to and extending from the top plate for connection to a first column of the building to align the first column with the base, wherein the alignment portion is spaced away from the bottom plate; wherein the alignment portion comprises a first alignment plate and a second alignment plate each connected to and extending from the top plate to form an interior angle between the first and second alignment plates; wherein the interior angle faces the drainage aperture.

[0008] The top plate may be connected to a first wall of the plurality of walls and extends from the first wall to connect to an oppositely disposed second wall of the plurality of walls. A top surface of the top plate may be level with or beyond a top edge of the first and second walls. The top plate may be welded to the alignment portion.

[0009] The bottom plate may be connected to the first wall and extends from the first wall to connect to the oppositely disposed second wall. The bottom plate may define another drainage aperture.

[0010] At least one of the first alignment plate and the second alignment plate may be offset from a wall of the plurality of walls of the base to define a shoulder on the top plate. The first alignment plate and the second alignment plate may define fastener apertures extending between respective internal and external surfaces of the alignment plates, wherein each of the internal surfaces of the alignment plates faces the drainage aperture and each of the external surfaces of the alignment plates faces the shoulder, wherein the fastener apertures are spaced away from the top plate and are each configured to receive a fastener above the shoulder.

[0011] The connector may further comprise a stub portion connected to the shoulder, wherein the stub portion comprises a wall extending from the top plate away from the bottom plate, the wall surrounding the alignment portion and configured to receive an end of the first column to space said end away from the top plate. The stub portion may be welded to the top plate. The stub portion may extend from the top plate to approximately 25% to 30% of the length of the alignment portion and below the fastener apertures. The stub portion may abut the external surfaces of the alignment plates to expose the shoulder on the top plate.

[0012] The alignment portion may be an angle extrusion wherein the first alignment plate and the second alignment plate are perpendicularly connected to each other. The interior angle between the first and second alignment plates may be about 90 degrees.

[0013] The base may comprise an extruded hollow portion comprising the top plate, the bottom plate, the first wall, and the second wall. For example, the base may comprise an extruded hollow portion such as a square hollow section (SHS), wherein the top plate, the bottom plate, the first wall, and the second wall are the walls of the SHS.

[0014] The top plate, the bottom plate, and the plurality of walls of the base may be separate components that are welded together. For example, the plates may be welded together to form a box section.

[0015] Some embodiments relate to a frame for a building module, comprising: a plurality of beams, wherein a first beam of the plurality of beams is connected to a second beam of the plurality of beams by a first one of the connector as disclosed herein.

[0016] Some embodiments relate to a building module, comprising: a first frame according to the frame as disclosed herein, wherein the first frame is reinforced by a plurality of rafters and purlins to form a roof frame;a second frame according to the frame as disclosed herein, wherein the second frame is reinforced by a plurality of floor joists to form a base frame; and a plurality of columns, each one of the plurality of columns comprising a roof end and a base end, the roof end configured to be connected to the roof frame and the base end configured to be connected to the base frame; wherein each one of the plurality of columns is respectively connected to the roof frame and the base frame by the connector as disclosed herein.

[0017] Some embodiments relate to a modular building, comprising a plurality of the building modules as disclosed herein, wherein adjacent building modules are connected by a plurality of pins and plates.

[0018] Some embodiments relate to a kit of parts for a modular building or building module, comprising: a plurality of columns; a plurality of beams; a plurality of reinforcement members; and a plurality of connectors configured to connect the plurality of beams to the plurality columns; wherein the plurality of connectors is the connector as disclosed herein.Brief Description of Drawings

[0019] In the accompanying drawings, sample dimensions are provided. To avoid confusion, reference numbers are underlined where sample dimensions are present in the drawing. Embodiments are described in further detail below, by way of example, with reference to the accompanying drawings, in which:

[0020] Fig. l is a perspective view of a connector, according to some embodiments;

[0021] Fig. 1 A is a perspective view of a modular building comprising a plurality of building modules, according to some embodiments;

[0022] Fig. IB is a section view of the modular building of Fig. 1 A, according to some embodiments;

[0023] Fig. 1C is a perspective view of a connection plate connecting a lower portion of four adjacent columns of the modular building of Fig. 1 A, according to some embodiments;

[0024] Fig. ID is a perspective view of a connection plate connecting an upper portion of four adjacent columns of the modular building of Fig. 1 A, according to some embodiments;

[0025] Fig. IE is a section view showing a connection detail of a roof frame and a column of the modular building of Fig. 1 A, according to some embodiments;

[0026] Fig. IF is a section view showing a connection detail of a roof frame, a base frame, and a column of the modular building of Fig. 1 A, according to some embodiments;

[0027] Fig. 2 is a plan view of a roof frame for the modular building and building module of Fig. 1A, according to some embodiments;

[0028] Fig. 2A is a section view showing a connection detail of a roof frame and a base frame of the modular building of Fig. 1 A, according to some embodiments;

[0029] Fig. 3 is a plan view of a base frame for the modular building and building module of Fig. 1A, according to some embodiments;

[0030] Figs. 4A and 4B are perspective views of a connector for the modular building and building module of Fig. 1 A, according to some embodiments, wherein Fig. 4A is a view at a first corner of the building module of Fig. 1 A and Fig. 4B is a view at a second comer of the building module of Fig. 1 A;

[0031] Fig. 5 is a perspective view of a connector for the modular building and building module of Fig. 1A, according to some embodiments;

[0032] Fig. 6 is a side view of the connector of Fig. 5 as used in a modular building and building module, according to some embodiments;

[0033] Fig. 7A is a plan view of the connector of Fig. 6, according to some embodiments;

[0034] Fig. 7B is a plan view showing a connection detail of four adjacent columns of the modular building of Fig. 1 A, according to some embodiments;

[0035] Figs. 8 A and 8B are plan views of a connector for the modular building and building module of Fig. 1A, according to some embodiments; and

[0036] Fig. 9 is a perspective view of a connector for the modular building and building module of Fig. 1A, according to some embodiments.Detailed Description

[0037] The present disclosure relates to a connector for a modular building, and modular buildings formed by connecting components thereof using the connector.

[0038] An example of a modular building may be a structure that is intended for temporary use. In this context, “temporary” refers to the structure being designed to be disassembled after a period of time. The period of time may be days, weeks, months, or several years. For example, concerts and sporting events may have buildings around the venue to provide hospitality, merchandise, or entertainment for attendees. In multipurpose venues, these buildings may need to be built and disassembled quickly to cooperate with other events that happen at the same venue during the year. By comparison, longer-term use of modular buildings may be suitable for schools, where student enrolment numbers may fluctuate between years, requiring a building to be quickly erected to minimise disruption to the rest of the school campus. Thesebuildings can then be disassembled and removed if student enrolment numbers decrease, or if a permanent building has been completed elsewhere.

[0039] To facilitate the quick assembly and disassembly of the modular building, the modular building may be formed as subcomponents or subassemblies that are held together by one or more connectors. The connectors may also be beneficial in locating subcomponents relative to each other, such that one subcomponent may be guided into position to be connected with another subcomponent. Accordingly, connectors can facilitate fast assembly and minimise assembly error and defects.

[0040] An example of a connector for a modular building or building module will now be described with reference to Fig. 1. The connector 10 is configured to connect to a column 20 and a beam 30, for example a column and beam that is part of the modular building or building module. In some embodiments, the connector 10 comprises a base 12 and an alignment portion 14 connected to and extending from the base 12. The column 20 may be a tube, such as a square hollow section (SHS) having a bore 22.

[0041] The alignment portion 14 is configured to be received inside the bore 22 of the column 20, so that a base 24 of the column 20 abuts the base 12 of the connector 10. When the alignment portion 14 is received in the bore 22 of the column 20, the column 20 is aligned with the base 12 of the connector 10.

[0042] Advantageously, the alignment portion 14 guides the column 20 into appropriate alignment with the base 12 without requiring additional marking, measurement, spirit levelling, or the like. As will be appreciated, this saves time and accordingly, construction cost, while minimising human error, construction defects and other consequences of misalignment.

[0043] In some examples, the alignment portion 14 extends outwardly from the base 12, such that in use it aligns an axis of the column 20 and an axis of the beam 30 at a desired angle, such as perpendicular. As shown in Fig 1, in one example this isachieved by providing the alignment portion 14 extending outwardly and at the desired angle from a plane defined by the base 12 (such as a surface of the base 12), where the beam 30 is intended for connection to the base 12 co-planar to the defined plane. As a result, in use the column axis and beam axis will be aligned according to the defined angle. While a perpendicular angle (90 degrees) is shown in Fig 1, it will be appreciated that the connector 10 may be configured to accommodate any other desired angle. In this example, the defined plane is defined by a first surface abutting the alignment portion 14, and / or a second surface on an opposing side of the base 10 from the first surface. The second surface may, in use, be used to support the connector 10 on a surface (such as ground).

[0044] In some examples, the alignment portion 14 is configured to, in use, align the rotation of the column 20 with respect to the base 12. In some instances, this also provides an alignment of the rotation of the column 20 with respect to a beam 30 fastened to the connector 10. In Fig 1, the alignment portion 14 has a shape that is configured to align the column 20 at a desired rotational orientation relative to the base 12. For example, in Fig 1, the alignment portion 14 includes a first alignment plate 17 and a second alignment plate 18 that is shaped to match at least part of the shape of the bore 22 of the column 20. In some examples, the bore 22 may have a square or rectangular shape, defined by first and second inner surfaces that are perpendicularly arranged relative to each other to define an inner corner of the bore 22 that has an angle around 90 degrees. The first alignment plate 17 and the second alignment plate 18 may be perpendicularly arranged relative to each other to correspond to the perpendicular inner corner of the bore 22, as shown in Fig 1. Other arrangements may be used in other examples, depending upon the shape and configuration of the column to be received. Accordingly, when the alignment portion 14 is received in the bore 22 of the column 20, the first alignment plate 17 and the second alignment plate 18 respectively abut the first and second inner surfaces of the bore 22, and the column 20 is aligned with the base 12 of the connector 10 in the desired rotational orientation. In Fig 1, the angle between the first alignment plate 17 and the second alignment plate 18 is 90 degrees to match the internal 90 degree angle of the bore 22. Other angles may be useddepending on the internal angle of the bore and the desired rotational orientation of the column 20 on the base 12.

[0045] The alignment portion 14 may define apertures 16 configured to receive a fastener. The column 20 may define apertures 26 located to correspond with the apertures 16, so that when the base 24 of the column 20 abuts the base 12, the fastener may extend through both of the apertures 16, 26 to connect the column 20 and the alignment portion 14. Beneficially, in use aligning the connector apertures 16 and column apertures 26 provides an additional check that alignment and configuration of the connector 10 and column has been performed correctly. Moreover, providing the connector 10 with apertures 16 saves time during construction by providing holes through which fasteners, such as bolts, can be easily positioned.

[0046] The beam 30 may be welded to the base 12 of the connector 10. In this example, the beam 30 may be welded in alignment with, and co-planar to, the defined plane of the base 12 of the connector 10. In some examples, a guide may be provided to facilitate welding of the beam 30 in the appropriate location with respect to the connector 10, and this will be discussed further below.

[0047] As will be appreciated, a rigid body in three dimensional space has six degrees of freedom - three translational and three rotational. Accordingly, when aligning a column (for example, to a beam), six degrees of freedom have to be contended with in order to reach the appropriate alignment. The connector 10 described herein provides a guide for aligning a column 20 at a desired translation and rotation, for instance, with respect to a beam 30. In use, the connector 10 facilitates reduced construction time and costs, while minimising construction error.

[0048] Further embodiments of the connector 10 are described in further detail below with reference to Fig. 4A to Fig. 9. Examples of a modular building comprising building modules assembled using the connector will now be described with reference to Fig. 1A to Fig, 3.

[0049] Fig. 1 A shows a modular building 100, according to some embodiments. The modular building 100 may comprise a plurality of building modules 110, such as a first building module 110-1 and a second building module 110-2. The second building module 110-2 may be stacked on top of the first building module 110-1 to form a modular building 100 having two levels. The first building module 110-1 and the second building module 110-2 may be identical in size and shape. The identical size and shape of the building modules 110-1, 110-2 may facilitate the assembly of the modular building 100, such as when assembling a plurality of the building modules 110-1, 110-2 to create a building 100 with a large floor area over a single level or over multiple levels, such as two levels, three levels, four levels, or more.

[0050] Each one of the plurality of building modules 110 may comprise subcomponents or subassemblies, such as a roof frame 200 and a floor or base frame 300. The roof frame 200 and the base frame 300 may extend generally parallel to each other in a horizontal plane. The roof frame 200 and the base frame 300 may each comprise a plurality of roof beams 210 and floor beams 310 connected to each other to respectively define the roof frame 200 and the base frame 300. The roof frame 200 and the base frame 300 may be similarly sized to have a similar floor area as shown in Fig.1 A, although other sizes are possible depending on occupants’ needs and the building’s intended use. For simplicity, the building modules 110-1, 110-2 shown in Fig. 1 A are cuboid, although other shapes are possible depending on occupants’ needs and the building’s intended use.

[0051] The roof frame 200 and the base frame 300 may be connected to each other by a plurality of columns, such as columns 120 which are configured to extend vertically to connect the roof frame 200 and the base frame 300. When the second building module 110-2 is stacked on the first building module 110-1, the floor or base frame 300-2 of the second building module 110-2 is placed on top of the roof frame 200-1 of the first building module 110-1. The floor or base frame 300-1 of the first building module 110-1 forms the floor or base of the modular building 100, while the roof frame 200-2 of the second building module 110-2 forms the roof of the modular building 100.

[0052] Fig. IB is a section view of the modular building 100 of Fig. 1 A, as viewed in elevation. In some embodiments, a modular building comprises a plurality of modular building 100 placed side by side, wherein columns 120 are adjacent to each other. To restrain the movement of the adjacent modular buildings 100, adjacent columns 120 may be connected to each other. Adjacent columns 120 may be connected with bracing structure. In some embodiments, adjacent columns 120 are connected with connecting plates.

[0053] Fig. 1C shows a lower connection plate 130 connecting a lower portion of four adjacent columns 120, such as where the columns 120 meet the floor or base frame 300. The lower connection plate 130 may define a fastener aperture 132 configured to receive a fastener. The fastener aperture 132 may be positioned to align with a corresponding aperture in the column 120. The lower connection plate 130 may define pairs of the fastener aperture 132, wherein each pair of the fastener aperture 132 aligns with corresponding pairs of apertures in the column 120. The use of pairs of apertures restricts relative rotation between the column 120 and the lower connection plate 130. The lower connection plate 130 may be present on a plurality of faces of the columns 120 to increase the connection between the columns 120. For example, the lower connection plate 130 may be present on all four faces of the four adjoining columns.

[0054] Fig. ID shows an upper connection plate 140 connecting an upper portion of four adjacent columns 120, such as where the columns 120 meet the roof frame 200. The upper connection plate 140 may define a fastener aperture 142 configured to receive a fastener. The fastener aperture 142 may be positioned to align with a corresponding aperture in the column 120. The upper connection plate 140 may define pairs of the fastener aperture 132, wherein each pair of the fastener aperture 132 aligns with corresponding pairs of apertures in the column 120. The use of pairs of apertures restricts relative rotation between the column 120 and the upper connection plate 140. The upper connection plate 140 may be present on a plurality of faces of the columns 120 to increase the connection between the columns 120. For example, the upper connection plate 140 may be present on all four faces of the four adjoining columns.

[0055] The column 120 may comprise first end 122 and a second end 124. The column 120 may be around 3000mm in overall length. In some embodiments, the first end 122 may define a lower end of the column 120. The second end 124 may define an upper end of the column 120. The first end 122 may be configured to abut or engage with a stub portion 126 of a first connector. The second end 124 may be configured to abut or engage with a stub portion 126 of a second connector. For clarity, the stub portions 126 are shown in isolation, with the rest of the first and second connectors are not shown in Figs. 1C and ID. The stub portion 126 will be discussed in more detail below. The respective interfaces between the stub portions 126 at the first end 122 and the second end 124 may be covered by the lower and upper connection plates 130, 140. The connection plates 130, 140 may connect the respective stub portions 126 with the first end 122 and the second end 124.

[0056] The lower connection plate 130 and the upper connection plate 140 may be of similar configuration. The lower connection plate 130 and the upper connection plate 140 may be made from steel plate, measuring around 10mm thick. The fastener apertures 132, 142 in the lower and upper connection plates 130, 140 may align with the holes used to connect the column 120 to the roof and base frames 200, 300. Aligning the fastener apertures 132, 142 with these holes may simplify the assembly and disassembly of the modular buildings 100 by reducing the number of fasteners needed. Having the fasteners in the same location may improve safety by reducing the need for workers to check multiple locations.

[0057] Fig. IE shows the top roof frame 200-2 of the modular building 100. Further detail of the connection between the roof frame 200 and the column 120 is shown in Fig. IE. The top roof frame 200-2 and the column 120 are connected by a connector, such as the connector 10 shown in Fig. 1, and the connectors subsequently described herein. The top roof frame 200-2 may comprise a drain aperture 201. The drain aperture 201 may be connected to the connector 10 and a drain pipe 600 extending through the connector 10.

[0058] Fig. IF shows the intermediate roof frame 200-1 of the modular building 100. Further detail of the connection between the roof frame 200, the base frame 300, and the column 120 is shown in Fig. IF. The roof frame 200 and the column 120 are connected by a connector, such as the connector 10 shown in Fig. 1, and the connectors subsequently described herein. The base frame 300 and the column 120 are connected by a connector, such as the connector 10 shown in Fig. 1, and the connectors subsequently described herein. The intermediate roof frame 200-1 of the modular building 100 may comprise a drain aperture 201. The drain aperture 201 may be connected to the connector 10 and a drain pipe 600 extending through the connector 10.

[0059] Fig. 2 shows a roof frame 200, according to some embodiments. The roof frame 200 may comprise a plurality of beams 210 that are connected to each other to define a perimeter of the roof frame 200. In the embodiment shown, the roof frame 200 comprises a first end beam 220 and a second end beam 230 of the beams 210. The first end beam 220 and the second end beam 230 may be connected by first and second lateral beams 240, 250. The first end beam 220 and the second end beam 230 may be parallel, and the first and second lateral beams 240, 250 may be parallel, so that the end beams 220, 230 are perpendicular to the lateral beams 240, 250.

[0060] The end beams 220, 230 and the lateral beams 240, 250 may be connected to define comers of the roof frame 200. The corners of the roof frame 200 may align with corners of an adjoining base frame 300. The corners of the roof frame 200 and the corners of the adjoining base frame 300 may be connected by a column 120.

[0061] The roof frame 200 may comprise apertures defined in at least some of the end beams 220, 230 and the lateral beams 240, 250, wherein the apertures are configured to receive a respective pin or pin assembly 260. The apertures in the roof frame 200 may align with corresponding apertures defined in the base frame 300 of another module 110. Fig. 2A shows detail of the connection between the roof frame 200 and the base frame 300. The roof frame 200 and the base frame 300 comprise beams that are elongate along respective longitudinal axes, and the pin assembly 260 is configured to be received in the beams perpendicular to these longitudinal axes so as to restrictrelative movement of the roof frame 200 and the base frame 300 in the elongate direction. The pin assembly 260 may be received through the centre of the respective beam and extend perpendicularly through the longitudinal axes.

[0062] When the pin assembly 260 is received in the apertures, adjoining roof frame 200 and base frame 300 are held in alignment. The pin assembly 260 may be a pipe 262 configured to receive a bar 264 within a bore 266 of the pipe 262, wherein the bore 266 of the pipe 260 is covered with a plug 268 to retain the bar 264 within. The bar 264 may comprise a hollow portion. The pin assembly 260 may be a pipe 262 measuring around 70mm outer diameter, configured to receive a 40x25 hollow bar 264, with the bore 266 of the pipe 262 covered by a plug 268 measuring 50mm in diameter.

[0063] The connection of the adjoining roof frame 200 and base frame 300 may be reinforced by the connection of adjacent columns 120 by the lower connection plate 130 and / or by the upper connection plate 140. In some embodiments, beam connection plates are used to connect adjoining roof frame 200 and base frame 300, such as over larger spans. The beam connection plates may be placed at the ends of the beams of the roof frame 200 and base frame 300, and / or between the ends of the beams.

[0064] The roof frame 200 may comprise a plurality of rafters 270 and purlins 280. The rafters 270 and purlins 280 may be configured to provide structural reinforcement of the roof frame 200. The rafters 270 may be perpendicularly connected to the lateral beams 240, 250. The rafters 270 may support a roof load and direct it to the lateral beams 240, 250. The purlins 280 may be perpendicularly connected to the end beams 220, 230. The purlins 280 may support a roof load and direct it to the end beams 220, 230. The rafters 270 and purlins 280 may support a floor load from an adjoining base frame 300 of another module 110 that is connected above the roof frame 200. A ridge beam 290 may be placed along the longitudinal axis of the roof frame 200. The purlins 280 may extend generally parallel to the ridge beam 290 and on both sides of the ridge beam 290. The rafters 270 are arranged to extend perpendicularly to the rafters 280 and the ridge beam 290. The rafters 270 and purlins 280 are arranged perpendicularly to each other.

[0065] By way of example, the roof frame 200 shown in Fig. 2 may have beams 210 made of square hollow section (SHS), such as 150 x 6 SHS. The rafters 270 may be made of rectangular hollow section (RHS), such as 75 x 50 x 1.6 RHS. The purlins may be made of 25 x 25 x 1.6 SHS. A ridge beam 290 may be placed along the length of the roof frame 200, and be made of 75 x 50 x 1.6 RHS. The size and position of the beams 210, the rafters 270, the purlins 280, and the ridge beam 290 may be adjusted depending on the roof loads to be applied during use of the building 100. The roof frame 200 may be connected to columns 120 made of 125 x 6 SHS.

[0066] Fig. 3 shows a base frame 300, according to some embodiments. The base frame 300 may comprise a plurality of beams 310 that are connected to each other to define a perimeter of the base frame 300. In the embodiment shown, the base frame 300 comprises a first end beam 320 and a second end beam 330 of the beams 310. The first end beam 320 and the second end beam 330 may be connected by first and second lateral beams 340, 350. The first end beam 320 and the second end beam 330 may be parallel, and the first and second lateral beams 340, 350 may be parallel, so that the end beams 320, 330 are perpendicular to the lateral beams 340, 350.

[0067] The end beams 320, 330 and the lateral beams 340, 350 may be connected to define comers of the base frame 300. The corners of the base frame 300 may align with comers of an adjoining roof frame 200. The comers of the roof frame 200 and the corners of the adjoining base frame 300 may be connected by a column 120.

[0068] The base frame 300 may comprise apertures defined in at least some of the end beams 320, 330 and the lateral beams 340, 350, wherein the apertures are configured to receive a respective one of the pin or pin assembly 260. The apertures in the base frame 300 may align with corresponding apertures defined in the roof frame 200 of another module 110. When the pin assembly 260 is received in the aperture, adjoining roof frame 200 and base frame 300 are held in alignment.

[0069] The base frame 300 may comprise a plurality of floor joists 370. The floor joists 370 may be configured to provide structural reinforcement of the base frame 300.The floor joists 370 may be perpendicularly connected to the lateral beams 340, 350. The floor joists 370 may support a floor load and direct it to the lateral beams 340, 350. The floor load may be the load of occupants or objects in the building 100 or module 110. Joists 370 are generally perpendicular to opposing lateral beams 340, 350, and parallel to opposing end beams 320, 330.

[0070] By way of example, the base frame 300 shown in Fig. 3 may have beams 310 made of 150 x 6 SHS. The floor joists 370 may be made of 75 x 50 x 5 RHS. The size and position of the beams 310 and the floor joists 370 may be adjusted depending on the floor loads to be applied during use of the building 100. The base frame 300 may be connected to columns 120 made of 125 x 6 SHS.

[0071] Further embodiments of the connector will now be described.

[0072] In some embodiments, the roof frame 200 and / or the base frame 300 further comprises a connector 400, such as shown in Figs. 4 A and 4B. The connector 400 may comprise one of the end beams 220, 230, 320, 330, and an alignment portion 410 connected to and extending from the respective end beam 220, 230, 320, 330. The alignment portion 410 may be configured to align and connect the roof frame 200 with the column 120. The alignment portion 410 may be configured to align and connect the base frame 300 with the column 120.

[0073] In some embodiments, the roof frame 200 and / or the base frame 300 comprises a first one 400-1 of the connector 400, wherein the first one of the connector 400-1 comprises one of the end beams 220, 230, 320, 330 and an alignment portion 410-1 welded to the end beam where the column 120 is to be positioned.

[0074] For example, Figs. 4A and 4B show a connector 400-1 comprising a first end beam 220 of the roof frame 200 and an alignment portion 410-1 welded to the first end beam 220 where the column 120 is to be positioned. The alignment portion 410-1 may be welded to the first end beam 220 at a first end 221 of the first end beam 220, such as shown in Fig. 4A. Another alignment portion 410-1 may be welded to the first endbeam 220 at an opposite, second end 223 of the first end beam 220, such as shown in Fig. 4B, so that the first one of the connector 400-1 comprises the first end beam 220 and two of the alignment portion 410-1. Each of the alignment portion 410-1 may have a longitudinal axis, and the alignment portion 410-1 may be welded to a top surface of the first end beam 220 so that the longitudinal axis extends generally perpendicular to the top surface. A lateral beam, such as lateral beam 240, 250, may then be welded to the end beam 220 to in part define the roof frame 200. Forming the alignment portion 410-1 and the end beam 220 as separate components, and then welding them together, allows for customisation of the separate components to suit the requirements of the project. For example, some projects may require a larger size beam 220, but an unchanged size of alignment portion 410-1. Other projects may require the alignment portion 410-1 to be placed in a different location on the beam 220 compared to another project. While the alignment portion 410-1 and the beam 220 could be integrally formed, such as cast or milled from a single block of material, such a manufacturing process would likely involve higher tooling costs and higher material wastage than forming the alignment portion 410-1 and the beam 220 as separate components which are then welded together.

[0075] The first end beam 220 may also be referred to as a base 420 of the connector 400-1. The first one of the connector 400-1 may accordingly comprise the alignment portion 410-1 and the base 420-1, wherein the alignment portion 410-1 is welded to the base 420-1 and extending therefrom for connection to a first column, such as column 120, to align the first column with the base 420-1. The first end beam 220 may comprise a top plate 222 and a bottom plate 224, wherein the top and bottom plates 222, 224 are connected by a plurality of walls 226. The alignment portion 410-1 may be welded to the top plate 222 to be connected to a first column, such as column 120. The alignment portion 410-1 may align the first column 120 with the base 420, wherein the alignment portion 410-1 is spaced away from the bottom plate 224.

[0076] A drainage aperture or drainage hole 430 may be defined in the end beam, such as in the top plate 222. In some embodiments, a drainage hole 430 is formed in at least one of the top plate 222, bottom plate 224, and walls 226. For example, thedrainage hole 430 may be formed in the top plate 222 and the bottom plate 224. The drainage hole 430 may be centrally disposed in the top plate 222.

[0077] The drainage hole 430 may receive a drain pipe (not shown) configured to direct rainwater from a roof of the building 100. The drain pipe may be external to the column 120. In some embodiments, the column 120 comprises a hollow portion such as a bore, and the drain pipe passes through the bore of the column 120 and into the drainage hole 430. Utility cables, such as for electricity and data, may be run though the bore 620 of the column 120, separate to the drain pipe 600. A similar configuration may apply to the base frame 300, wherein the alignment portion 410 may be welded to one of the beams 310, such as a first end beam 320. The first end beam 320 may also be referred to as a base 420 of the connector 400-1. The first end beam 320 may comprise a top plate 322 to which the alignment portion 410 is welded. The first end beam 320 may define a drainage hole 330. For example, the drainage hole 330 may be defined in the top plate 322. In some embodiments, the drainage hole 430 is formed in at least one of the top plate 322, bottom plate 324, and walls 326 of the first end beam 320.

[0078] The alignment portion 410 may be an extrusion. The alignment portion 410 may be an angle extrusion, such as an equal angle, defining an internal corner having an internal angle and an external corner having an external angle. The alignment portion 410 may be an angle extrusion, such as an equal angle measuring 100 x 100 x 10. The alignment portion 410 may be a channel extrusion, such as a U or C extrusion defining internal corners and internal angles and corresponding external comers and external angles. The alignment portion 410 may be on the same face of the end beam as the drainage hole 430, such as a top face of the top plate 222. The alignment portion 410 may face the drainage hole 430, wherein the internal angle(s) of the angle extrusion or channel are closer to the drainage hole 430 than the external angle(s). The connector 400-1 may further comprise a stub portion, such as stub portion 126, which may be connected to and extend from the beam 220 around the alignment portion 410. To allow visibility of the entirety of the alignment portion 410, the stub portion of the connector 400-1 is not shown in Figs. 4A and 4B. However, the stub portion of theconnector 400-1 is arranged in a similar manner to the stub portion of the connector 500, shown in Figs. 5 and 6 and subsequently described below.

[0079] In some embodiments, the end beams 220, 230 and the lateral beams 240, 250 are indirectly connected. The roof frame 200 and / or the base frame 300 may further comprise a connector 500, such as shown in Fig. 5.

[0080] Figs. 5, 6, and 7A show a connector 500 for a modular building, according to some embodiments. Fig. 5 is a perspective view of the connector 500, while Fig. 6 is a side view of the connector 500 as part of an example building module 110. Fig. 7A is a top view of the connector 500 as part of an example building module 110.

[0081] Turning to Fig. 5, the connector 500 may comprise an alignment portion 510 and a base 520. The alignment portion 510 may have a longitudinal axis, and the alignment portion 510 may be welded to a top surface of the base 520 so that the longitudinal axis extends generally perpendicular to the top surface. In some embodiments, the connector 500 further comprises a drainage aperture or hole 530. The base 520 may comprise a top plate 522. The top plate 522 may define the drainage hole 530. The drainage hole 530 may be centrally disposed in the top plate 522. The base 520 may further comprise a bottom plate 524, wherein the top plate 522 and the bottom plate 524 are connected by a plurality of walls 526.

[0082] A beam, such as roof beam 210 or floor beam 310, may be welded to one of the walls 526. Perpendicular walls of the walls 526 may be connected to beams, such as an end beam 220 and a lateral beam 240, so that these beams 220, 340 are also perpendicularly arranged relative to each other. The alignment portion 510 may then extend perpendicularly to the beams 220, 340. For example, beam 220 may be welded to the base 520 and extend therefrom in an X axis direction, beam 340 may be welded to the base 520 and extend therefrom in a perpendicular Y axis direction, and alignment portion 510 may be welded to the base 520 such that its longitudinal axis extends from the base 520 in a Z axis direction that is perpendicular to both the X and Y axes.

[0083] In some embodiments, the drainage hole 530 is formed in at least one of the top plate 522, bottom plate 524, and walls 526. For example, the drainage hole 530 may be formed in the top plate 522 and the bottom plate 524. Drainage holes in the top plate 522 and the bottom plate 524 could be aligned.

[0084] The top plate 522 may be connected to a first wall 527 of the plurality of walls 526 and extend from the first wall 527 to connect to an opposing second wall 528 of the plurality of walls 526. The bottom plate 524 may be connected to the first wall 527 and extends from the first wall 527 to connect to the opposing second wall 528. The base 520 may comprise a hollow portion defined at least in part by the top plate 522, the bottom plate 524, the first wall 527, and the second wall 528.

[0085] In some embodiments, the alignment portion 510 may be an extrusion. The alignment portion 510 may be an angle extrusion, such as an equal angle shown in Fig. 5, defining an internal corner 512 having an internal angle and an external corner 514 having an external angle. The alignment portion 510 may be an angle extrusion, such as an equal angle measuring 100 x 100 x 10. The alignment portion 510 may be a channel extrusion, such as a U or C extrusion defining internal corners and internal angles and corresponding external comers and external angles. The alignment portion 510 may be on the same face of the end beam as the drainage hole 530, such as a top face of the top plate 522. The alignment portion 510 may face the drainage hole 530, wherein the internal angle(s) and internal corner 512 of the angle extrusion or channel are closer to the drainage hole 530 than the external angle(s) and external comer 514.

[0086] The alignment portion 510 may comprise a first alignment plate 516 and a second alignment plate 518. Each of the alignment plates 516, 518 may be connected to and extend from the top plate 522. Each of the alignment plates 516, 518 may comprise respective internal and external surfaces. In some embodiments, each of the internal surfaces of the alignment plates faces the drainage aperture or hole 530, and each of the external surfaces of the alignment plates faces away from the drainage hole 530. Each of the alignment plates 516, 518 may be approximately 100mm long and 10mm thick, wherein the thickness is measured as a distance between the internal andexternal surfaces of the alignment plates 516, 518. Each of the alignment plates 516, 518 may define at least one fastener aperture 519 configured to receive a bolt or other fastener. The fastener apertures 519 may extend between the respective internal and external surfaces of the alignment plate. The fastener aperture 519 may align with a corresponding aperture in the column 120 so that the column 120 may be secured to the alignment plates 516, 518 via the bolt or fastener. As shown in Fig. 6 for example, the aperture 519 may be configured to receive an M16 bolt. The fastener apertures 519 may be formed in the alignment plates 516, 518 to be spaced away from the top plate 522. A first one of the fastener apertures 519 may be formed in the alignment plates 516, 518 spaced away from the top plate 522 along a first length of the alignment plates 516, 518. A second one of the fastener apertures 519 may be formed in the alignment plates 516, 518 spaced away from the top plate 522 along a second length of the alignment plates 516, 518, wherein the second length is greater than the first length.

[0087] In some embodiments, the alignment plates 516, 518 are connected to each other to form an interior angle between the first and second alignment plates 516, 518. The interior angle may be about 90 degrees. The alignment plates 516, 518 may each have a longitudinal axis. Each of the alignment plates 516, 518 may be welded to a top surface of the base 520 so that their longitudinal axes extend generally perpendicular to the top surface.

[0088] As shown in Fig. 5, with further reference to Fig. 6, a top surface 523 of the top plate 522 may be level with or extend beyond (or extend outwardly from) a top edge of the first and second walls 527, 528. This may provide a groove 521 to accommodate a fillet weld between the top plate 522 and the first and second walls 527, 528. The groove 521 may also accommodate a fillet weld between the adjoining beam 350 and the bottom plate 524. The groove 521 may extend around a perimeter of the top plate 522. The top surface 523 may be level with or above a top edge of the first and second walls 527, 528 to prevent the formation of a recess in the base 520 where moisture may accumulate on the top surface 523. The top surface 523 may be level with a corresponding top surface of an adjacent beam 210, 310, allowing a wall panel to be easily accommodated without a significant rebate or notch required. Abottom surface 525 of the bottom plate 524 may be level with or extend beyond (or extend outwardly from) a bottom edge of the first and second walls 527, 528. This may provide a groove 529 (Fig. 6) to accommodate a fillet weld between the bottom plate 524 and the first and second walls 527, 528. The groove 529 may also accommodate a fillet weld between the adjoining beam 350 and the bottom plate 524. The groove 529 may extend around a perimeter of the bottom plate 524.

[0089] In some embodiments, the plurality of walls 526 is integrally formed. The plurality of walls 526 may be an extrusion, such as a square hollow section (SHS). The SHS used may be 150 x 6 SHS with a length approximately measuring 140mm to 150mm to form the base 520 with a generally cube shape. The 150 x 6 SHS may define a hollow interior of approximately 138mm. In embodiments where the top surface 523 of the top plate 522 extends beyond a top edge of the first and second walls 527, 528, the thickness of the top plate 522 may add an additional 5-10mm to the 140mm length of the SHS so that the base 520 is a 150mm cube. In embodiments where the bottom surface 525 of the bottom plate 524 extends beyond a bottom edge of the first and second walls 527, 528, the thickness of the bottom plate 524 may add an additional 5-10mm to the 140mm length of the SHS so that the base 520 is a 150mm cube. In embodiments where both the top surface 523 and the bottom surface 525 extends beyond the first and second walls 527, 528, the thickness of the top and bottom plates 522, 524 may add an additional 5- 10mm to the 140mm length of the SHS so that the base 520 is a 150mm cube. The top plate 522 may be approximately 10mm thick. The top plate 522 may be approximately 136mm to 138mm square to fit within the 138mm hollow of the 150 x 6 SHS. The bottom plate 524 may be approximately 10mm thick. The bottom plate 524 may be approximately 136mm to 138mm square to fit within the 138mm hollow of the 150 x 6 SHS.

[0090] In some embodiments, separate plates are combined to form an equivalent combination to the SHS. For example, the base 520 may comprise a first plate defining the first wall 527, a second plate defining the opposite second wall 528, and a third and fourth plates extending between and welded to the first and second plates to form a square tube.

[0091] The connector 500 may define a first end 540 and a second end 550. The first end 540 and the second end 550 may be at opposite ends of the base 520. Where the base 520 is cuboid, the first end 540 may be a first comer 540 and the second end 550 may be a second corner 550 formed at corners of the base 520. The drainage hole 530 may be disposed closer towards the first corner 540 than the second corner 550. The alignment portion 510 may be disposed closer towards the second corner 550 than the first corner 540.

[0092] Turning to Fig. 6, the alignment portion 510 may be connected to and extend from the top plate 522 for connection to a first column, such as column 120, to align the first column with the base 520. Alignment portion 510 extends outwardly from, and perpendicular to, the top face or top surface 523 of the top plate 522. The connector 500 may further comprise a stub portion 126 connected to and extending from the base 520. The stub portion 126 is configured to receive the first end 122 of the column 120 to space the first end 122 of the column 120 away from the base 520, such as away from the top plate 522. The stub portion 126 may have the same cross section dimensions of the column 120 so that when the first end 122 of the column 120 abuts the stub portion 126, the outer wall of the column 120 is coplanar with the outer wall of the stub portion 126. For example, the column 120 and the stub portion 126 may be cut from the same size of hollow section, such as 125 x 6 SHS. The stub portion 126 may comprise a wall 128 extending from the base 520 in the same direction as the alignment portion 510; for example, parallel to a longitudinal axis of the alignment portion 510. The stub portion 126 may be welded to the top plate 522 and extend from the top plate 522 away from the bottom plate 524. The stub portion 126 ends below the fastener apertures 519 in the alignment portion 510 so as to avoid blocking the fastener apertures 519. When the column 120 is slid onto the alignment portion 510 and abuts the stub portion 126, the fastener apertures 519 in the alignment portion 510 are aligned to be level with the corresponding apertures in the column 120 to facilitate entry of the fasteners to the fastener apertures 519 during assembly of the column 120 with the alignment portion 510. During disassembly of the column 120 with the alignment portion 510, the fasteners are removed from apertures 519 and the column slid awayfrom the stub portion 126 and off the alignment portion 510. To allow visibility of the entirety of the alignment portion 510, the stub portion 126 is not shown in Fig. 5.

[0093] In some embodiments, the wall 128 surrounds the portion of the alignment portion 510 connected to the top plate 522, so that when the first end 122 of the column 120 is received in abutting arrangement with the stub portion 126, the first end 122 of the column 120 is spaced away from the top plate 522 by the height of the wall 128. The height of the wall 128 may be sufficient to space the first end 122 of the column 120 away from the top plate 522 to provide clearance between the first end 122 and a window subsill that is placed on the beam (such as beam 350) connected to the base 520 of the connector 500. The height of the wall 128 may be around 50mm. The stub portion 126 may extend from the top plate 522 to approximately 25% to 30% of the length of the alignment portion 510. For example, in embodiments where the height of the wall 128 is around 50mm, the length of the alignment portion 510 is approximately 200mm, of which 150mm extends above the top edge of the wall 128. The wall 128 of the stub portion 126 may encircle the alignment portion 510, wherein the alignment portion 510 extends through the stub portion 126 in a similar manner to a person’s neck extends through a collar of a shirt.

[0094] The alignment portion 510 may be spaced away from the bottom plate 524. The drainage hole 530 may receive a drain pipe 600 configured to direct rainwater from a roof of the building 100 or module 110. The drain pipe 600 may be external to the column 120. In some embodiments, the column 120 comprises a wall 610 defining a hollow portion 620 such as a bore, and the drain pipe 600 passes through the bore 620 of the column 120 and into the drainage hole 530. Utility cables, such as for electricity and data, may be run though the bore 620 of the column 120, separate to the drain pipe 600. In the example building module 110 of Fig. 6, the drain pipe 600 is shown as a pipe having a 3.2mm thick wall defining a bore with a 42.4mm diameter.

[0095] Fig. 7A is a plan view of the connector 500 in use, where the connector 500 is engaged with the column 120. As shown in Fig. 7A, in use, the first alignment plate 516 may abut a first interior face 612 of the wall 610 of column 120, and the secondalignment plate 518 may abut a perpendicular second interior face 614 of the wall 610 of column 120, so as to facilitate the positioning of the column 120 relative to the base 520. As shown in Fig. 7A, the first alignment plate 516 may limit X-direction movement (translation along the X axis) of the column 120 along the base 520, while the second alignment plate 518 may limit Y-direction movement (translation along the Y axis) of the column 120 along the base 520. The alignment plates 516, 518 may be located on the base 520 so that some of the outer surfaces of the walls 610 of column 120 line up with some of the walls 526 of the base 520.

[0096] As shown in Fig. 7 A, the alignment plates 516, 518 may be connected to each other as part of an angle extrusion. The first alignment plate 516 and the second alignment plate 518 may be perpendicularly connected to each other. The combined shape of the first alignment plate 516 and the second alignment plate 518 may match at least part of the shape of the bore of the column 120. For example, the combined shape of the first alignment plate 516 and the second alignment plate 518 may be an L shaped angle which corresponds to an internal comer of the bore of the column 120.

[0097] In the embodiments shown, the alignment portion 510 is positioned to receive a column 120 that is smaller than the base 520. The alignment portion 510 is connected to the base 520 so as to position the column 120 at or towards the first corner 540 of the base 520, so that the first corner 540 and the adjacent faces of the column 120 and the base 520 align or are substantially close to being aligned. The alignment portion 510 and the base 520 may be welded together. Forming the alignment portion 510 and the base 520 as separate components, and then welding them together, allows for customisation of the separate components to suit the requirements of the project. For example, some projects may require a larger size of the base 520, or a base 520 made of thicker plate, but an unchanged size of the alignment portion 510. Other projects may require the alignment portion 510 to be placed in a different location on the base 520 compared to another project. While the alignment portion 510 and the base 520 could be integrally formed, such as cast or milled from a single block of material, such a manufacturing process would likely involve higher tooling costs and higher materialwastage than forming the alignment portion 510 and the base 520 as separate components which are then welded together.

[0098] The alignment of the column 120 and the base 520 may define a shoulder 700 at a second comer 550 of the base 520 where the remainder of the base 520 (particularly the top plate 522) extends beyond the smaller footprint of the column 120 sitting on the top plate 522. The second comer 550 may be opposite the first corner 540. The alignment plates 516, 518 may be offset from the second corner of the base 520. The first corner 540 may be an outer corner of the building module 110, and the second comer 550 may be an inner corner of the building module 110. The shoulder 700 may therefore be formed on the side of the inner, second corner of the building module 110. The alignment portion 410 may similarly have a shoulder 700 as formed around the alignment portion 510 and the inner corner of the building module 110. The stub portion 126 may be positioned at the first corner 540 of the base 520 and be offset from the second corner 550 of the base 520 to expose the shoulder 700 on the top plate 522. The external surfaces of the alignment plates 516, 518 may face the shoulder 700. The inside walls of the stub portion 126 may abut the external surfaces of the alignment plates 516, 518 so that the shoulder 700 remains exposed.

[0099] In some embodiments, the alignment portion 510 is disposed on the base plate 522 so that the external corner 514 faces the shoulder 700. In other words, the external corner 514 is disposed on the side of the base plate 522 defining the shoulder 700. The shoulder 700 may be at an inner comer of the building module 110 so that the apertures 519 may also face the inner corner of the building module 110, therefore obscuring the apertures 519 and its associated bolts from external view. A fastener may be inserted into fastener apertures 519 from the side of the connector 500 on which the shoulder 700 is formed. When a fastener is received in the fastener apertures 519, the fastener is thus disposed above the shoulder 700. As shown in Fig. 7A, the shoulder 700 is configured so that the apertures 519 (and thus, the heads of fasteners inserted therein) of the alignment portion 510 align with and face the beams 220, 240. The beams 220, 240 are configured to receive a wall panel, which may define a wall cavity.Accordingly, when wall panels are installed in the building module 110 along thebeams 220, 240, the apertures 519 and its associated fastener heads (e.g. bolt heads) are hidden by the wall panel, such as in the wall cavity, and thus hidden from external view. This may provide an aesthetic improvement. There may also be safety advantages by restricting access to the bolts, particularly from outside the module 110.

[0100] Fig. 7B shows an advantage of locating the shoulder 700 at an inner corner of the building module 110. Fig. 7B is a partial plan view of a modular building 100 comprising four of the building module 110, showing a connection detail of four adjacent columns such as in Figs. 1C and ID. The four building modules 110 are placed adjacent to each other, so that the first, outer corner 540 of each building module 110 are adjacent to each other. The floor beams 320, 350 of adjacent building modules 110 may be touching or almost touching. The floor beams 320, 350 are configured to receive a wall panel, which may define a wall cavity.

[0101] Adjacent columns 120 may be positioned so that the columns 120 are touching or almost touching. Adjacent columns 120 may be secured to each other, for example by the lower connection plate 130 (or upper connection plate 140 at the roof frame 200). The alignment of the fastener apertures 132 of the lower connection plate 130 with the apertures 519 of the alignment portion 510 allows the same bolt or fastener to be used to secure the alignment plates 516, 518 to the column 120 and the lower connection plate 130, thereby simplifying manufacture and assembly and disassembly of the modular building 100. Similarly, where upper connection plate 140 is used to connect columns 120, the alignment of the fastener apertures 142 of the upper connection plate 140 with the apertures 519 of the alignment portion 510 allows the same bolt or fastener to be used to secure the alignment plates 516, 518 to the column 120 and the upper connection plate 140, thereby simplifying manufacture and assembly and disassembly of the modular building 100.

[0102] The shoulder 700 of each building module 110 may be formed on the inner, second comer 550 of each building module 110. The shoulder 700 of each building module 110 may accordingly define a space to receive the lower connection plate 130. As viewed from above, the lower connection plate 130 may be contained within theperimeter of the shoulder 700. If the shoulder 700 were not present on the inner corner 550 of the building module 110, the lower connection plate 130 may not be accommodated in the wall cavity formed above the beams 320, 350. This may result in the lower connection plate 130 being visible from the inside of the building module 110. The shoulder 700 allows the lower connection plate 130 to be hidden by the wall panel or within the wall cavity.

[0103] Turning to Figs. 8A and 8B, the alignment plates 516, 518 of the alignment portion 510 may be connected to each other as part of an angle-like extrusion (Fig. 8 A) or a channel-like extrusion (Fig. 8B). In some embodiments, such as shown in Figs. 8A and 8B, the alignment plates 516, 518 are not connected to each other, but are arranged at an angle relative to each other to effectively act as an angle extrusion in retaining the column 120 in position. Despite not being connected to each other, the first alignment plate 516 may limit X-direction movement (translation along the X axis) of the column 120 along the base 520, while the second alignment plate 518 may limit Y-direction movement (translation along the Y axis) of the column 120 along the base 520. Fig. 8B shows an embodiment comprising a third alignment plate 517, where third alignment plate 517 may further limit Y-direction movement (translation along the Y axis) of the column 120 along the base 520 in conjunction with the second alignment plate 518. The alignment plates 516, 517, 518 cooperate to act in a similar manner to a channel extrusion.

[0104] The combined shape of the first alignment plate 516, the second alignment plate 518, and the third alignment plate 517 may match at least part of the shape of the bore of the column 120. In some examples, the bore may have a square or rectangular shape, defined by first, second and third inner surfaces that are perpendicularly arranged relative to each other to define one or more inner corners of the bore that each have an angle around 90 degrees. The first alignment plate 516, the second alignment plate 518, and the third alignment plate 517 may be arranged relative to each other to correspond to the one or more of the perpendicular inner corners of the bore, as shown in Figs. 8A and 8B. Other arrangements may be used in other examples, depending upon the shape and configuration of the column to be received. Accordingly, when thealignment portion 510 is received in the bore of the column 120, the first alignment plate 516, the second alignment plate 518, and the third alignment plate 517 respectively abut the first, second and third inner surfaces of the bore, and the column 120 is aligned with the base 520 of the connector 500 in the desired rotational orientation. The first alignment plate 516, the second alignment plate 518, and the third alignment plate 517 may cooperate to restrain rotation of the column 120 relative to the base 520 along the Z axis. In Fig. 8A, the angle between the first alignment plate 516 and the second alignment plate 518 is 90 degrees to match the internal 90 degree angle of the bore of the column 120. Other angles may be used depending on the internal angle(s) of the bore and the desired rotational orientation of the column 120 on the base 520.

[0105] Fig. 9 shows an embodiment of a connector 900. The connector 900 is similar to the connector 500, comprising an alignment portion 910 and a base 920. In some embodiments, the connector 900 further comprises a drainage aperture or hole 930. The alignment portion 910 and the base 920 may be welded together. The base 920 may comprise a top plate 922 defining the drainage hole 930. The base 920 may further comprise a bottom plate 924, wherein the top plate 922 and the bottom plate 924 are connected by a plurality of walls 926. In some embodiments, the drainage hole 930 is formed in at least one of the top plate 922, bottom plate 924, and walls 926. For example, the drainage hole 930 may be formed in the top plate 922 and the bottom plate 924. Forming the alignment portion 910 and the base 920 as separate components, and then welding them together, allows for customisation of the separate components to suit the requirements of the project. For example, some projects may require a larger size of the base 920, or a base 920 made of thicker plate, but an unchanged size of the alignment portion 910. Other projects may require the alignment portion 910 to be placed in a different location on the base 920 compared to another project. While the alignment portion 910 and the base 920 could be integrally formed, such as cast or milled from a single block of material, such a manufacturing process would likely involve higher tooling costs and higher material wastage than forming the alignment portion 910 and the base 920 as separate components which are then welded together.

[0106] The base 920 may further comprise a second aperture 932. The second aperture 932 may be defined in one of the plurality of walls 926. The second aperture 932 may be configured to provide a further passage for drainage, for example for the drain pipe 600 to extend therethrough. In some embodiments, the second aperture 932 is configured to receive a peg or spigot extending from one of the beams 210, 310 that is to be connected to the base 920. The peg may facilitate alignment of the beam 210, 310 so that the beams 210, 310 are positioned correctly, for example, relative to the base 920 and / or the column 120 to be attached to the alignment portion 910.

[0107] The alignment portion 910 may be an angle extrusion, such as an equal angle shown in Fig. 9, defining an internal corner 912 having an internal angle and an external comer 914 having an external angle. The alignment portion 910 may be a channel extrusion, such as a U or C extrusion defining internal corners and internal angles and corresponding external comers and external angles. The alignment portion 910 may be on the same face of the end beam as the drainage hole 930, such as a top face of the top plate 922. The alignment portion 910 may face the drainage hole 930, wherein the internal angle(s) of the angle extrusion or channel are closer to the drainage hole 930 than the external angle(s).

[0108] The alignment portion 910 may comprise a first alignment plate 916 and a second alignment plate 918. Each of the alignment plates 916, 918 may be connected to and extend outwardly from the top plate 922. Each of the alignment plates 916, 918 may define at least one aperture 919 configured to receive a bolt or other fastener. The aperture 919 may align with an corresponding aperture in the column 120 so that the column 120 may be secured to the alignment plates 916, 918 via the bolt or fastener.

[0109] In the present disclosure, various sizes of beams and columns are disclosed. It will be appreciated by persons skilled in the art that other sizes of beams and columns are possible depending on the building’s intended use. For example, the wall thickness, length, height, or width of these structural members may be adjusted depending on the loads to be applied during use of the structure. The connectors disclosed herein to form frames, building modules, and modular buildings may accordingly provide the abilityto customise the frames, building modules, and modular buildings, such as by mixing and matching the appropriate size and strength of structural members.

[0110] The embodiments of the modular building or building module may be supplied as a kit of parts. The kit may comprise a plurality of columns as disclosed herein. The kit may comprise a plurality of beams as disclosed herein. The kit may comprise a plurality of reinforcement members as disclosed herein. The connector, the beams and the reinforcement members may be welded together to form subcomponents of the building module, such as the roof frame or the base frame. The kit may comprise a plurality of connectors as disclosed herein configured to connect the plurality of beams to the plurality of columns via the connector to form a building module. A plurality of the building modular may be combined to form a modular building, such as by connecting adjacent columns with the connecting plates as disclosed herein.

[0111] Steel may be used to manufacture the connector and the building modules. Steel provides a balance in strength, cost, ease of working, and commercial availability of sizes and shapes. The welding of separate steel components to form the connector is preferred over forming the connector as a single piece, such as by milling or casting the connector.

[0112] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A connector for a modular building or building module, the connector comprising: a base comprising a top plate and a bottom plate connected by a plurality of walls, the top plate defining a drainage aperture; an alignment portion connected to and extending from the top plate for connection to a first column of the building to align the first column with the base, wherein the alignment portion is spaced away from the bottom plate; wherein the alignment portion comprises a first alignment plate and a second alignment plate each connected to and extending from the top plate to form an interior angle between the first and second alignment plates; wherein the interior angle faces the drainage aperture.

2. The connector of claim 1, wherein the top plate is connected to a first wall of the plurality of walls and extends from the first wall to connect to an oppositely disposed second wall of the plurality of walls.

3. The connector of claim 2, wherein the bottom plate is connected to the first wall and extends from the first wall to connect to the oppositely disposed second wall.

4. The connector of any one of claims 1 to 3, wherein a top surface of the top plate is level with or beyond a top edge of the first and second walls.

5. The connector of any one of claims 1 to 4, wherein the top plate is welded to the alignment portion.

6. The connector of any one of claims 1 to 5, wherein at least one of the first alignment plate and the second alignment plate are offset from a wall of the plurality of walls of the base to define a shoulder on the top plate.

7. The connector of claim 6, wherein the first alignment plate and the second alignment plate define fastener apertures extending between respective internal and external surfaces of the alignment plates, wherein each of the internal surfaces of the alignment plates faces the drainage aperture and each of the external surfaces of the alignment plates faces the shoulder, wherein the fastener apertures are spaced away from the top plate and are each configured to receive a fastener above the shoulder.

8. The connector of claim 7, further comprising a stub portion connected to the shoulder, wherein the stub portion comprises a wall extending from the top plate away from the bottom plate, the wall surrounding the alignment portion and configured to receive an end of the first column to space said end away from the top plate.

9. The connector of claim 8, wherein the stub portion is welded to the top plate.

10. The connector of claim 9, wherein the stub portion extends from the top plate to approximately 25% to 30% of the length of the alignment portion and below the fastener apertures.

11. The connector of any one of claims 8 to 10, wherein the stub portion abuts the external surfaces of the alignment plates to expose the shoulder on the top plate.

12. The connector of any one of claims 1 to 11, wherein the alignment portion is an angle extrusion wherein the first alignment plate and the second alignment plate are perpendicularly connected to each other.

13. The connector of any one of claims 1 to 12, wherein the base comprises an extruded hollow portion comprising the top plate, the bottom plate, the first wall, and the second wall.

14. The connector of any one of claims 1 to 13, wherein the bottom plate defines another drainage aperture.

15. The connector of any one of claims 1 to 12, wherein the top plate, the bottom plate, and the plurality of walls of the base are separate components that are welded together.

16. The connector of any one of claims 1 to 15, wherein the interior angle is about 90 degrees.

17. A frame for a building module, comprising: a plurality of beams, wherein a first beam of the plurality of beams is connected to a second beam of the plurality of beams by a first one of the connector of any one of claims 1 to 16.

18. A building module, comprising: a first frame according to the frame of claim 17, wherein the first frame is reinforced by a plurality of rafters and purlins to form a roof frame; a second frame according to the frame of claim 17, wherein the second frame is reinforced by a plurality of floor joists to form a base frame; and a plurality of columns, each one of the plurality of columns comprising a roof end and a base end, the roof end configured to be connected to the roof frame and the base end configured to be connected to the base frame; wherein each one of the plurality of columns is respectively connected to the roof frame and the base frame by the connector of any one of claims 1 to 16.

19. A modular building, comprising a plurality of the building modules of claim 18, wherein adjacent building modules are connected by a plurality of pins and plates.

20. A kit of parts for a modular building or building module, comprising a plurality of columns; a plurality of beams; a plurality of reinforcement members; and a plurality of connectors configured to connect the plurality of beams to the plurality columns;wherein the plurality of connectors is the connector of claims 1 to 16.

21. The steps, features, integers, compositions and / or compounds disclosed herein or indicated in the specification of this application individually or collectively, and any and all combinations of two or more of said steps or features.

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