Modular Pitched Roof Units Off-Site Assembly
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Solution Overview
Problem
The existing methods for constructing and converting pitched roof structures are inefficient, leading to increased on-site work time, health and safety risks, and potential delays due to adverse weather conditions, as well as challenges in transporting and assembling modular roof units without compromising structural integrity.
Innovation Solution
A method involving the use of demountable support beam apparatus and modular pitched roof units, where units are assembled off-site and lifted using a three-point lift system, allowing for accurate spacing and alignment with spacers, and secured with releasable means to withstand transport and installation stresses, reducing the need for on-site scaffolding and minimizing health risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional on-site assembly methods are used for pitched roof structures, then flexibility and adaptability are maintained, but construction time increases and productivity decreases
Solution Approach 1:
The pitched roof structure is divided into modular roof units that can be pre-assembled off-site and then transported to the construction location. Each module includes pre-assembled truss units with roof covering, allowing for rapid on-site installation while maintaining structural integrity.
Solution Approach 2:
Roof modules are pre-assembled and pre-covered off-site before transportation to the construction location. This preliminary preparation includes assembling truss units, applying underlay, fixing tiling battens, and installing roof tiles in a controlled environment, which significantly reduces on-site construction time.
2Adaptability or versatility
If on-site assembly is performed, then adaptability to site conditions is maintained, but exposure to adverse weather conditions increases causing delays
Solution Approach 1:
The roof modules are completely assembled and covered off-site in a controlled factory environment, protecting the construction process from adverse weather conditions. All critical construction activities occur indoors, eliminating weather-related delays while the modules are transported to the site for final installation.
Solution Approach 2:
The completed roof module acts as an intermediary that bridges the factory production environment and the on-site installation. It encapsulates all vulnerable construction activities within a protected module that can withstand transportation and installation stresses while protecting the building interior during the construction process.
3Productivity
If modular roof units are transported to site, then on-site construction time is reduced, but structural integrity during transport may be compromised
Solution Approach 1:
The demountable support beam apparatus provides dynamic support to the modular roof units during transportation and installation. The support beams can be adjusted and positioned to distribute loads appropriately, and the releasable securing means allow the structure to be secured during transport and then easily released for final assembly, adapting to different structural requirements.
Solution Approach 2:
The releasable securing means are pre-installed on the modular roof units to provide protective support during transportation. These securing mechanisms are designed to withstand transport stresses and can be easily engaged and disengaged, providing beforehand protection against structural damage while maintaining assembly flexibility.
4Ease of operation
If traditional scaffolding is used for on-site assembly, then worker safety is maintained, but health and safety risks increase due to working at height
Solution Approach 1:
By dividing the roof structure into pre-assembled modules, the complex on-site assembly process is eliminated. Workers only need to perform simple lifting and positioning operations at ground level or minimal height, significantly reducing the time spent working at height and associated safety risks while maintaining adequate safety through proper lifting procedures.
Data Source
Figure 1~1a
Figure 2~2a
Figure 3~3a
AI summary
A method of assembly of at least one tiled pitched roof unit module 1. The method comprises making several truss units 2 off site each incorporating a floor/ceiling joist and roof rafters 6 fixed to the joist to form a support framework for a roof covering. Preferably a floor or ceiling is mounted on the joists. The module roof covering isa tiles that are fixed to the rafters. The module is transported to, and assembled/installed on the tops of the walls of a building at, a building site. Preferably several modules can be used on a single building and each module is lifted/hoisted using a releasable securing device. Also claimed is a method of assembling on the walls of a building a tiled pitched roof module by lifting the unit module at opposite ends and positioning the module on the tops of the building walls. Also claimed is a modification of the method of assembly which contains no tiles and using a releasable securing assembly to transfer the module comprising a number of trusses onto wall tops at a building site. Also claimed is a demountable support and lifting beam 92.