WO1998044211A1 - Portable flat-pack building - Google Patents

Portable flat-pack building Download PDF

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Publication number
WO1998044211A1
WO1998044211A1 PCT/GB1998/000969 GB9800969W WO9844211A1 WO 1998044211 A1 WO1998044211 A1 WO 1998044211A1 GB 9800969 W GB9800969 W GB 9800969W WO 9844211 A1 WO9844211 A1 WO 9844211A1
Authority
WO
WIPO (PCT)
Prior art keywords
die
base platform
portable
sections
budding
Prior art date
Application number
PCT/GB1998/000969
Other languages
French (fr)
Inventor
David M. Macwatt
Original Assignee
Sujunara Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sujunara Limited filed Critical Sujunara Limited
Priority to NZ338035A priority Critical patent/NZ338035A/en
Priority to EP98914956A priority patent/EP0972117A1/en
Priority to AU69259/98A priority patent/AU6925998A/en
Publication of WO1998044211A1 publication Critical patent/WO1998044211A1/en

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34321Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts mainly constituted by panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34315Structures characterised by movable, separable, or collapsible parts, e.g. for transport characterised by separable parts
    • E04B1/34317Set of building elements forming a self-contained package for transport before assembly
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/38Connections for building structures in general
    • E04B1/61Connections for building structures in general of slab-shaped building elements with each other
    • E04B1/6108Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together
    • E04B1/6116Connections for building structures in general of slab-shaped building elements with each other the frontal surfaces of the slabs connected together by locking means on lateral surfaces

Definitions

  • the present invention relates to prefabricated buildings, and in particular to buildings which may be easily assembled and disassembled.
  • Such temporary accommodation may be provided in the form of a rigid walled construction which is prefabricated and transported to a selected location in fully assembled or partly assembled form.
  • This type of structure is necessarily bulky to transport, particularly if fully assembled, and often requires a complex and lengthy assembly procedure when it is delivered to the selected location in its disassembled form.
  • This type of construction is often used for semipermanent installations such as for supplementary office space at a factory premises, or as long term building site accommodation.
  • temporary accommodation may take the form of non- rigid structures such as tents or even inflatable buildings and the like. While these have advantages of being very much more portable and more rapidly assembled or erected, they do not generally offer adequate protection from extremes of weather. This type of construction is typically favoured where accommodation must be provided very quickly, in large quantities or at remote locations, for example, army field camps or humanitarian relief camps.
  • a portable building comprising: a base platform; side walls adapted to releasably engage with the base platform along the sides thereof; gable end walls adapted to releasably engage with the base platform across the width thereof; a pair of pitched roof sections each having a width which does not exceed half the width of the base platform; and a bridge section adapted to couple the pair of pitched roof sections together.
  • Figure 1 shows a perspective view of a portable building according to the present invention, in assembled condition with a cut-away portion showing internal detail;
  • Figure 2 shows a right side view of the portable building of figure 1;
  • Figure 3 shows a front view of the portable building of figure 1 ;
  • Figure 4 shows a rear view of the portable building of figure 1
  • Figure 5 shows a front view of the portable building of figure 1 with the door and front panel units removed to reveal gable end wall framework;
  • Figure 6 shows: (a) a front elevation of a single base platform section of the portable building of figure 1; (b) a plan view of two adjacent base platform sections without floor covering to reveal the framework; (c) a side elevation of a single base platform section; and (d) a side elevation of a base platform section connecting probe;
  • Figure 7 shows an inside view of two adjacent wall panels of the portable building of figure 1 ;
  • Figure 8 shows: (a) an inside view; and (b) an end view of the pitched roof panels of the portable building of figure 1;
  • Figure 9 shows: (a) a lateral cross-sectional view; and (b) an underside plan view of the bridge section connecting opposing pitched roof sections of the portable building of figure 1 ;
  • Figure 10 shows schematic diagrams of the coupling mechanisms from (a) side wall section to base platform (side elevation); (b) side wall section to base platform (front elevation); and (c) gable end wall to base platform;
  • Figures 11a, l ib and lie show schematic diagrams of three different coupling mechanisms used to engage side wall sections; pitched roof sections; and gable end walls to one another;
  • Figure 12 shows (a) a front view of the disassembled and flat- packed building; and (b) a side view of the disassembled and flat-packed building; and
  • Figure 13 shows schematic diagrams of a lifting socket and handle arrangement.
  • FIG. 1 With reference to figures 1 to 4 there is shown a presently preferred portable building 1 according to the present invention.
  • the components of the building will be described by referring to the front of the building as the gable end shown towards the left foreground of figure 1 and as shown in figure 3, and the sides of the building being those extending along the longitudinal axis (as shown, eg, in figure 2).
  • Terms such as top, bottom, upper, lower, horizontal, upright and vertical etc are construed as referring to aspects of the components as they are normally oriented in the assembled condition.
  • the building 1 comprises a base platform 2 which is formed from two detachable sections 3, 4 which are connected to one another along line 5 in a manner to be described hereinafter.
  • a gable end wall 6, 7 is provided at the back and front end respectively of the building. Note that in figure 1, the back end gable wall 6 is not visible, while the front gable end wall 7 is shown only by its internal frame, the cladding panels having been cut away.
  • Side walls are constructed from two side wall sections 8, 9 (figure 2) located adjacent one another on one side of the building, and a further two side wall sections 10, 11 on the opposite side of die building. ⁇ a l ⁇ M 1 PCT/GB98/00969 98/44211
  • the building roof is also formed in two longitudinal halves 12, 13, each of which comprises a pair of opposing pitched roof sections 14, 15 which are connected to one another by a bridge section 16.
  • the gable end walls 6, 7, side wall sections 8—11 , and pitched roof sections 14, 15 are preferably fabricated from a number of rigid panels 20 of insulation material sandwiched between an outer skin which may be metal, plastic or other suitable weatherproof material.
  • the rigid panels 20 preferably include tongue and groove type profiles on at least opposite (front and back) edges 21, 22 in order mat an effective seal may be made between adjacent panels.
  • Bottom and top edges 23, 24 of the rigid panels preferably do not provide tongue and groove profiles.
  • the panels 20 are attached to a number of welded metal frameworks 30, 31, 32 corresponding respectively to side wall sections 8, 9, 10, 11; to gable end walls 6, 7; and to pitched roof sections 14, 15.
  • the panels may be attached by bolting, rivetting or other similar method, through the panels 20 and into appropriate members of the framework 30, 31 , 32 of the section.
  • the panels 20 may be secured to the respective framework by way of a suitable adhesive, for example, epoxy resin.
  • a suitable adhesive for example, epoxy resin.
  • the frameworks 30, 31, 32 are formed from square or rectangular cross- section tubing.
  • the bridge sections 16 may also be formed from rigid panels 20 of insulation material secured to a frame in a similar manner, and also preferably include strips of flashing material along their longitudinal edges to overlay adjacent edges of the pitched roof sections as discussed later in connection with figure 9.
  • Figure 5 shows a detailed front view of a preferred framework 31 used for gable end walls 6, 7.
  • the framework 31 includes a door frame 40 — 43 which enables the installation of a door unit 44 (figure 3) into one of the gable end walls 7.
  • the same frame 40 — 43 enables the installation of a window unit 45 (figure 4) into the other gable end wall 6.
  • the frame 40—43 may be left vacant for attachment of a tunnel unit (not shown) which may be installed to link adjacent buildings together, after assembly, in similar manner to the connection of railway carriages.
  • FIG. 6 shows detail of the base platform sections 3, 4. For clarity, these are shown without floor panels 50, 51 , 52 (figure 1) attached, so that detail of the underlying framework is visible.
  • the base platform section 3 framework comprises a rectangular frame 55—58 strengthened by a lateral member 59 and cross-braces 60 (figure 6b), although it will be understood that a number of configurations are possible.
  • Beneath the rectangular frame, as shown in figures 6a and 6c are three longitudinal supports, referred to in this specification as skids 70, 71 , 72.
  • the skids are preferably formed from rectangular cross- section steel tubing which enables the insertion of rectangular section probes 73, 74, 75 into one of the base platform sections 3 (figure 6b).
  • the probes can be locked into position using any suitable method, such as pins (not shown) which simultaneously pass through holes 76 (figure 6d) in the probes 73, 74, 75 and corresponding holes 77 in the skids 70, 71 , 72.
  • the second base platform section 4 includes three corresponding skids 78, 79, 80 which receive the probes 73, 74, 75 when the two sections 3, 4 are brought together. The two sections 3, 4 are then locked together using further pins, at least through probes 73 and 75 and skids 78, 80. It will be understood that insertion of pins into the centre probe 74 may not be convenient if access is difficult.
  • the three probes 73, 74, 75 are of different lengths. This is to allow easier coupling of the base platform sections 3, 4 to one another.
  • the centre probe 74 is the longest (by approximately 30 cm) so that it may be first aligned and engaged with the centre skid 79 without interference from other skid / probe pairs.
  • the section 4 can then be easily twisted or otherwise oriented to bring skid 78 into alignment with the next longest probe 73, which will then ensure that as the two sections 3, 4 are brought together, the third probe 75 should align automatically with skid 80. In this way, it is only necessary to locate one skid to a probe at any one time. It will be understood that the same effect can be obtained with probes 73, 74, 75 of identical lengths but different depths of insertion into skids 70, 71 , 72.
  • Figure 7 shows detail of die framework 30 of side wall sections 8—11.
  • the framework 32 of each of the side wall sections 8—11 includes a suitable fixing mechanism to attach the side wall section to an adjacent side wall section, to the adjacent base platform section 3, 4 and to an adjacent pitched roof section 14, 15. Fixing mechanisms will be described in greater detail hereinafter.
  • Figure 8 shows detail of the framework of pitched roof sections 14, 15.
  • the framework 32 of each of the pitched roof sections 14, 15 includes a suitable fixing mechanism to attach the pitched roof section 14, 15 to: an adjacent pitched roof section 15, 14; to an adjacent side wall section 8—11 ; and to an adjacent bridge section 16. Details of the bridge section connection mechanism are shown in figure 9.
  • Each bridge section 16 links together opposing pitched roof sections 14, 15.
  • the bridge section includes a rectangular frame 85—88 in which the lateral frame elements 85, 87 include an angled pin 90, 91 extending from each end thereof.
  • the pin angle corresponds to the pitch angle of the pitched roof sections 14, 15, and engages with corresponding frame members of the pitched roof sections framework.
  • the angled pins 90, 91 may be locked into position using locking pins or other suitable mechanism.
  • Each bridge section includes an insulated panel 92 coupled to die framework 85—88 as previously discussed, and a flashing 93 which extends over the adjacent pitched roof sections 14, 15 when me building is assembled.
  • the two base platform sections are coupled together using the probes 73, 74, 75, as discussed in connection with figure 6.
  • Each of the gable end walls 6, 7 includes three pins 100 (figure 10c) coupled to the lowermost horizontal frame member 101 (figure 5) which extend downwardly so as to engage with a corresponding hole 102 in the frame member (eg. 55) of base platform section 3, 4 (passing through floor panels 50, 51, 52), when the gable end wall 7 is dropped into place on the base platform section 4.
  • Side wall sections 8—11 each include two "L-shaped" pins 105 coupled to die lowermost horizontal frame member 106 (figure 7) which extend downwardly so as to engage with a corresponding slot 107 in the frame member (eg. 56, 58) of base platform section 3, 4 (passing through floor panels 50, 51, 52), when d e side wall section is dropped into place.
  • each section is then slid sideways toward die gable end wall 7 so that the horizontal portion 108 of the L-shaped pin 105 engages underneath the top wall of rectangular cross-section frame members 56 or 58.
  • Adjacent side wall sections 8 and 10 are therefore inserted first and slid towards gable end wall 7, followed by side wall sections 9, 11 which are slid up to adjacent side wall sections 8, 10.
  • side wall sections 9, 11 which are slid up to adjacent side wall sections 8, 10.
  • Vertical framework members 110, 111 , 112 and 113 of the gable end walls 6, 7 and side walls 8—11 are linked using appropriate bracket and link members selected from those shown in figures 11a to lie.
  • Figure 11a shows adjacent frame members 120, 121 each including a distal side bracket 122 and angled link member 123 to maintain the frame members in engagement with one another.
  • Figure l ib shows adjacent frame members 120, 121 in which frame member 120 includes a distal side bracket 122 while frame member 121 includes an adjacent side bracket 124 and angled link member 125 maintains me frame members in engagement with one another.
  • Figure l ie shows adjacent frame members 120, 121 in which frame member 120 includes an adjacent side bracket 124 and frame member 121 includes a distal side bracket 122 and angled link member 126 maintains the frame members in engagement with one another.
  • bracket and link members used will depend upon the juxtaposition of the adjacent section frame members and die accessibility of the sides diereof.
  • the bracket and link members of figure 11a are used to connect adjacent side wall sections 8—11 to one another and adjacent pitched roof sections 14, 15 to one another, ie. where the sections lie edge to edge in the same plane.
  • die frame members 120 and 121 both correspond to vertical edge frame members 112, 113 of the side wall sections, and sloping edge frame members of the pitched roof sections.
  • bracket and link members of figure l ib are used to connect the pitched roof sections to the adjacent gable end walls 6, 7, ie. where the sections lie edge to edge in orthogonal planes.
  • the frame member 120 corresponds to pitched top edge frame members of the gable end walls 6, 7, and d e frame member 121 corresponds to the adjacent sloping edge frame members of the pitched roof sections 14, 15.
  • me bracket and link members of figure l ie are used to connect: (a) the side wall sections 8—11 to adjacent pitched roof sections 14, 15; and (b) side wall sections 8—11 to adjacent gable end walls 6, 7, ie. where the sections lie edge to edge in ormogonal or oblique planes.
  • me frame member 120 corresponds to the lower longitudinal edge frame members of the pitched roof sections and the frame member 121 corresponds to die top edge of an adjacent side wall section; or the frame member 120 corresponds to vertical edge frame members 110, 111 of the gable end walls 6, 7, and die frame member 121 corresponds to the adjacent vertical edge frame members of the side wall members.
  • the pitched roof sections 14, 15 have a lower longitudinal edge frame member 128 which is presented at an angle to d e pitched roof panel to enable engagement with die top edge frame members of the side walls.
  • each link member 123, 125, 126 is retained on one of the adjacent sections by way of a wire link 130.
  • each section edge 120, 121 includes at least two of the bracket and link members spaced apart along the edge, although more may be used if required.
  • connection widi figure 11 has been specifically designed to avoid die use of any screws or bolts in the assembly of the building, since direaded portions of screws and bolts may evenmally become damaged dirough cross-direading or the like .
  • die use of screws or bolts requires a greater time for assembly and disassembly and a greater degree of precision in aligning components.
  • link members become difficult to release from their respective brackets, the simple sliding action required may be effected widi die assistance of a hammer or the like.
  • FIG 12 the disassembly and stowage of die portable building 1 will now be discussed in detail.
  • the profile of the building 1 has been designed to offer significant advantages in me way die building components may be flat-packed for shipping.
  • pitched roofs have die disadvantage that me widdi of die pitched roof sections (ie. viewed from a gable end of the building) is necessarily greater than die half widdi of the building, not even allowing for overhang of the pitched roof sections over side walls. Thus, it is not normally possible to flat pack pitched roof sections in the same plane adjacent one anodier, and space is often wasted.
  • the provision of a bridge section 16 between the two opposing pitched roof sections 14, 15 serves two important purposes.
  • the pitched roof section widths w R are made to be less than or equal to half die widdi of the building base platform w B (figure 4) thus enabling die two pitched roof sections to be laid side by side (ie. in me same plane) when flat packing.
  • the bridge section 16 also offers further advantages. Firstly, it provides a flat platform when the building is assembled onto which a water tank may readily be attached.
  • die relatively small sections 16 can be adapted to receive air conditioning apparams in me form of air scrubbers or the like, particularly where the buildings are being used for military purposes or can be readily replaced widi sections 16 incorporating me appropriate hardware.
  • each base platform section 3, 4 includes a pair of leg sockets 140, 141 on each side of die platform section. These each receive a corresponding leg 142 for die purposes of giving me building ground clearance and levelling adjustment for uneven ground.
  • the legs 142 may be height adjustable in leg sockets 140, 141 using suitable known memods.
  • a first base platform section 4 is used as die package base.
  • Note diat figure 12a shows the package 200 from the side of die base platform section 4
  • figure 12b shows the package 200 from the front of the base section 4.
  • Two side wall sections 8, 10 are then placed side by side on die base platform 4 with die panel 20 facing downwards and framework 30 facing upwards.
  • the two gable end walls 6, 7 are then placed one on top of die odier, panel 20 facing panel 20 and in die same orientation, on top of die side wall sections 8, 10.
  • the two further side wall sections 9, 11 are then placed over the top of die gable end 7 widi die framework 31 facing downwards.
  • diat die two gable ends 6, 7 leave two triangular voids 201, 202 which are used for a storage box 203 and a heating / cooking stove 204. It is noted diat die voids 201 , 202 are somewhat thicker than twice me diickness of the gable end sections 6, 7, because die voids 201 , 202 also effectively include die diickness of die frameworks 30 of the side wall sections 8—11 above and below.
  • die skids 70, 71 , 72 leaves a cavity into which is installed die two bridge sections 16, two verandah sections 206 to be described later, and guttering and downpipes 207 for rainwater collection.
  • the three probes 73, 74, 75 may be locked inside skids 70, 71 , 72 of the base platform section 3.
  • the flat-pack 200 so formed is held togedier by die use of some of me levelling legs 142 which can be located into respective sockets 140, 141 of die two base platform sections and locked into place.
  • multiple flat-packs may be stacked together using a set of stacking legs 210, 211, 212 which have fingers 214, 215, 216 which engage with successive skid ends in me stack.
  • the same pin mechanisms which lock the probes into place within the skids when die building is assembled may be used to lock the stacking legs 210—212 into the skid ends.
  • four of die disassembled and flat-packed buildings 200 may be stacked in the same volume as mat occupied by one assembled building.
  • the buddings are then readUy transportable by lorry or aircraft in stacks without needing containerization, further reducing die cost of transport.
  • the base platform sections may be provided widi lifting sockets 250 which are coupled to die outer edges of outer skids 70, 72, 78, 80, each of which includes a slot 251 widi a wide access from below which is adapted to receive a handle 252 having a collar 253 which engages behind die slot 252 as indicated in dashed outline on figure 13b.
  • An alternative configuration of lifting sockets is depicted in figure 6c.
  • the buddings may be provided widi verandah floor sections 206 which are supported at eidier end of the building on support plates 260 which can be inserted into the ends of die various skids 70, 71 , 72, 78, 79, 80.
  • diat die sealing of lateral joins between the adjacent pitched roof sections and side wall sections can be accomplished by die use of die tongue and groove profiles of the panels 20.
  • Sealing of corner joins, eg. between gable end walls and side wall sections or pitched roof sections, and between pitched roof sections and side wall sections, can be accomplished by overlapping joins and or die provision of flashing material.
  • Guttering and rainwater collection hardware can be affixed to die pitched roof edges in customary manner.

Abstract

A portable building (1) which can be rapidly assembled and disassembled and flat packed for easy transportation without containerization comprises a base platform (2); side walls adapted to releasably engage with the base platform (2) along the sides thereof; gable end walls (6,7) adapted to releasably engage with the base platform (2) across the width thereof; a pair of pitched roof sections (14, 15) each having a width which does not exceed half the width of the base platform (2), and a bridge section (16) adapted to couple the pair of pitched roof sections (14, 15) together. The sections of the building are generally formed of metal skinned-insulation panels (20) supported on a framework (30, 31, 32), and all sections can be interlocked together without use of screws or bolts. The bridge section (16) of the roof provides a platform for water supply tanks, air filtration or scrubber units and the like.

Description

PORTABLE FLAT-PACK BUILDING
The present invention relates to prefabricated buildings, and in particular to buildings which may be easily assembled and disassembled.
There is a widespread need for the provision of temporary accommodation of various types. Such temporary accommodation may be provided in the form of a rigid walled construction which is prefabricated and transported to a selected location in fully assembled or partly assembled form. This type of structure is necessarily bulky to transport, particularly if fully assembled, and often requires a complex and lengthy assembly procedure when it is delivered to the selected location in its disassembled form. This type of construction is often used for semipermanent installations such as for supplementary office space at a factory premises, or as long term building site accommodation.
Alternatively, temporary accommodation may take the form of non- rigid structures such as tents or even inflatable buildings and the like. While these have advantages of being very much more portable and more rapidly assembled or erected, they do not generally offer adequate protection from extremes of weather. This type of construction is typically favoured where accommodation must be provided very quickly, in large quantities or at remote locations, for example, army field camps or humanitarian relief camps.
There is therefore a need for a rigid walled construction which offers a high degree of shelter from extremes of weather, but which can be very rapidly assembled and disassembled, and which can be easily transported to remote areas. In many applications, it is also advantageous if such temporary accommodation can be as self-contained as possible, not relying on external services or the like.
It is an object of the present invention to provide a portable building which is of a rigid walled construction, which provides a good degree of protection from the weather to its occupants, and which is very quickly assembled or disassembled.
It is a further object of the invention to provide a portable building which can be "flat packed" into a very compact form for transportation.
According to the present invention, there is provided a portable building comprising: a base platform; side walls adapted to releasably engage with the base platform along the sides thereof; gable end walls adapted to releasably engage with the base platform across the width thereof; a pair of pitched roof sections each having a width which does not exceed half the width of the base platform; and a bridge section adapted to couple the pair of pitched roof sections together.
Embodiments of the present invention will now be described with reference to the accompanying drawings in which:
Figure 1 shows a perspective view of a portable building according to the present invention, in assembled condition with a cut-away portion showing internal detail;
Figure 2 shows a right side view of the portable building of figure 1;
Figure 3 shows a front view of the portable building of figure 1 ; Figure 4 shows a rear view of the portable building of figure 1
Figure 5 shows a front view of the portable building of figure 1 with the door and front panel units removed to reveal gable end wall framework;
Figure 6 shows: (a) a front elevation of a single base platform section of the portable building of figure 1; (b) a plan view of two adjacent base platform sections without floor covering to reveal the framework; (c) a side elevation of a single base platform section; and (d) a side elevation of a base platform section connecting probe;
Figure 7 shows an inside view of two adjacent wall panels of the portable building of figure 1 ;
Figure 8 shows: (a) an inside view; and (b) an end view of the pitched roof panels of the portable building of figure 1;
Figure 9 shows: (a) a lateral cross-sectional view; and (b) an underside plan view of the bridge section connecting opposing pitched roof sections of the portable building of figure 1 ;
Figure 10 shows schematic diagrams of the coupling mechanisms from (a) side wall section to base platform (side elevation); (b) side wall section to base platform (front elevation); and (c) gable end wall to base platform;
Figures 11a, l ib and lie show schematic diagrams of three different coupling mechanisms used to engage side wall sections; pitched roof sections; and gable end walls to one another; Figure 12 shows (a) a front view of the disassembled and flat- packed building; and (b) a side view of the disassembled and flat-packed building; and
Figure 13 shows schematic diagrams of a lifting socket and handle arrangement.
With reference to figures 1 to 4 there is shown a presently preferred portable building 1 according to the present invention. Throughout the present specification, the components of the building will be described by referring to the front of the building as the gable end shown towards the left foreground of figure 1 and as shown in figure 3, and the sides of the building being those extending along the longitudinal axis (as shown, eg, in figure 2). Terms such as top, bottom, upper, lower, horizontal, upright and vertical etc are construed as referring to aspects of the components as they are normally oriented in the assembled condition.
The building 1 comprises a base platform 2 which is formed from two detachable sections 3, 4 which are connected to one another along line 5 in a manner to be described hereinafter. A gable end wall 6, 7 is provided at the back and front end respectively of the building. Note that in figure 1, the back end gable wall 6 is not visible, while the front gable end wall 7 is shown only by its internal frame, the cladding panels having been cut away. Side walls are constructed from two side wall sections 8, 9 (figure 2) located adjacent one another on one side of the building, and a further two side wall sections 10, 11 on the opposite side of die building. Λa lΛ M 1 PCT/GB98/00969 98/44211
The building roof is also formed in two longitudinal halves 12, 13, each of which comprises a pair of opposing pitched roof sections 14, 15 which are connected to one another by a bridge section 16.
The gable end walls 6, 7, side wall sections 8—11 , and pitched roof sections 14, 15 are preferably fabricated from a number of rigid panels 20 of insulation material sandwiched between an outer skin which may be metal, plastic or other suitable weatherproof material. The rigid panels 20 preferably include tongue and groove type profiles on at least opposite (front and back) edges 21, 22 in order mat an effective seal may be made between adjacent panels. Bottom and top edges 23, 24 of the rigid panels preferably do not provide tongue and groove profiles.
The panels 20 are attached to a number of welded metal frameworks 30, 31, 32 corresponding respectively to side wall sections 8, 9, 10, 11; to gable end walls 6, 7; and to pitched roof sections 14, 15. The panels may be attached by bolting, rivetting or other similar method, through the panels 20 and into appropriate members of the framework 30, 31 , 32 of the section.
In a further embodiment, the panels 20 may be secured to the respective framework by way of a suitable adhesive, for example, epoxy resin. This technique offers a potential advantage in that no bolt heads, rivet heads or other securing devices need project from the outer skin of panels 20, nor is there any need to penetrate the skins and insulation material of the panels 20 to insert the securing devices. Preferably, the frameworks 30, 31, 32 are formed from square or rectangular cross- section tubing. The bridge sections 16 may also be formed from rigid panels 20 of insulation material secured to a frame in a similar manner, and also preferably include strips of flashing material along their longitudinal edges to overlay adjacent edges of the pitched roof sections as discussed later in connection with figure 9.
Figure 5 shows a detailed front view of a preferred framework 31 used for gable end walls 6, 7. In the preferred embodiment, the framework 31 includes a door frame 40 — 43 which enables the installation of a door unit 44 (figure 3) into one of the gable end walls 7. For simplicity in the manufacturing process and flexibility in use of the portable buildings, the same frame 40 — 43 enables the installation of a window unit 45 (figure 4) into the other gable end wall 6. As an alternative, the frame 40—43 may be left vacant for attachment of a tunnel unit (not shown) which may be installed to link adjacent buildings together, after assembly, in similar manner to the connection of railway carriages.
Figure 6 shows detail of the base platform sections 3, 4. For clarity, these are shown without floor panels 50, 51 , 52 (figure 1) attached, so that detail of the underlying framework is visible. The base platform section 3 framework comprises a rectangular frame 55—58 strengthened by a lateral member 59 and cross-braces 60 (figure 6b), although it will be understood that a number of configurations are possible. Beneath the rectangular frame, as shown in figures 6a and 6c are three longitudinal supports, referred to in this specification as skids 70, 71 , 72. The skids are preferably formed from rectangular cross- section steel tubing which enables the insertion of rectangular section probes 73, 74, 75 into one of the base platform sections 3 (figure 6b). The probes can be locked into position using any suitable method, such as pins (not shown) which simultaneously pass through holes 76 (figure 6d) in the probes 73, 74, 75 and corresponding holes 77 in the skids 70, 71 , 72. The second base platform section 4 includes three corresponding skids 78, 79, 80 which receive the probes 73, 74, 75 when the two sections 3, 4 are brought together. The two sections 3, 4 are then locked together using further pins, at least through probes 73 and 75 and skids 78, 80. It will be understood that insertion of pins into the centre probe 74 may not be convenient if access is difficult.
In the preferred embodiment, the three probes 73, 74, 75 are of different lengths. This is to allow easier coupling of the base platform sections 3, 4 to one another. The centre probe 74 is the longest (by approximately 30 cm) so that it may be first aligned and engaged with the centre skid 79 without interference from other skid / probe pairs. The section 4 can then be easily twisted or otherwise oriented to bring skid 78 into alignment with the next longest probe 73, which will then ensure that as the two sections 3, 4 are brought together, the third probe 75 should align automatically with skid 80. In this way, it is only necessary to locate one skid to a probe at any one time. It will be understood that the same effect can be obtained with probes 73, 74, 75 of identical lengths but different depths of insertion into skids 70, 71 , 72.
Figure 7 shows detail of die framework 30 of side wall sections 8—11. The framework 32 of each of the side wall sections 8—11 includes a suitable fixing mechanism to attach the side wall section to an adjacent side wall section, to the adjacent base platform section 3, 4 and to an adjacent pitched roof section 14, 15. Fixing mechanisms will be described in greater detail hereinafter. Figure 8 shows detail of the framework of pitched roof sections 14, 15. The framework 32 of each of the pitched roof sections 14, 15 includes a suitable fixing mechanism to attach the pitched roof section 14, 15 to: an adjacent pitched roof section 15, 14; to an adjacent side wall section 8—11 ; and to an adjacent bridge section 16. Details of the bridge section connection mechanism are shown in figure 9.
Each bridge section 16 links together opposing pitched roof sections 14, 15. The bridge section includes a rectangular frame 85—88 in which the lateral frame elements 85, 87 include an angled pin 90, 91 extending from each end thereof. The pin angle corresponds to the pitch angle of the pitched roof sections 14, 15, and engages with corresponding frame members of the pitched roof sections framework. The angled pins 90, 91 may be locked into position using locking pins or other suitable mechanism.
Each bridge section includes an insulated panel 92 coupled to die framework 85—88 as previously discussed, and a flashing 93 which extends over the adjacent pitched roof sections 14, 15 when me building is assembled.
Assembly of me building will now be described in detail, with reference also to figures 10 and 11 which show a presently preferred set of releasable fixing mechanisms for engaging adjacent building sections to one another.
As a first step, the two base platform sections are coupled together using the probes 73, 74, 75, as discussed in connection with figure 6.
Each of the gable end walls 6, 7 includes three pins 100 (figure 10c) coupled to the lowermost horizontal frame member 101 (figure 5) which extend downwardly so as to engage with a corresponding hole 102 in the frame member (eg. 55) of base platform section 3, 4 (passing through floor panels 50, 51, 52), when the gable end wall 7 is dropped into place on the base platform section 4.
Side wall sections 8—11 each include two "L-shaped" pins 105 coupled to die lowermost horizontal frame member 106 (figure 7) which extend downwardly so as to engage with a corresponding slot 107 in the frame member (eg. 56, 58) of base platform section 3, 4 (passing through floor panels 50, 51, 52), when d e side wall section is dropped into place. For the side walls, however, each section is then slid sideways toward die gable end wall 7 so that the horizontal portion 108 of the L-shaped pin 105 engages underneath the top wall of rectangular cross-section frame members 56 or 58. Adjacent side wall sections 8 and 10 are therefore inserted first and slid towards gable end wall 7, followed by side wall sections 9, 11 which are slid up to adjacent side wall sections 8, 10. By appropriate relative positioning of the holes 102 and slots 107 in die base platform sections, only when the side wall sections are fully slid toward the gable end wall 7 can the opposite gable end wall 6 be dropped into position.
Vertical framework members 110, 111 , 112 and 113 of the gable end walls 6, 7 and side walls 8—11 are linked using appropriate bracket and link members selected from those shown in figures 11a to lie.
Figure 11a shows adjacent frame members 120, 121 each including a distal side bracket 122 and angled link member 123 to maintain the frame members in engagement with one another. Figure l ib shows adjacent frame members 120, 121 in which frame member 120 includes a distal side bracket 122 while frame member 121 includes an adjacent side bracket 124 and angled link member 125 maintains me frame members in engagement with one another. Figure l ie shows adjacent frame members 120, 121 in which frame member 120 includes an adjacent side bracket 124 and frame member 121 includes a distal side bracket 122 and angled link member 126 maintains the frame members in engagement with one another.
It will be understood that the type of bracket and link members used will depend upon the juxtaposition of the adjacent section frame members and die accessibility of the sides diereof. In the preferred embodiment, the bracket and link members of figure 11a are used to connect adjacent side wall sections 8—11 to one another and adjacent pitched roof sections 14, 15 to one another, ie. where the sections lie edge to edge in the same plane. As depicted in figure 1 la, die frame members 120 and 121 both correspond to vertical edge frame members 112, 113 of the side wall sections, and sloping edge frame members of the pitched roof sections.
In die preferred embodiment, the bracket and link members of figure l ib are used to connect the pitched roof sections to the adjacent gable end walls 6, 7, ie. where the sections lie edge to edge in orthogonal planes. As depicted in figure l ib, the frame member 120 corresponds to pitched top edge frame members of the gable end walls 6, 7, and d e frame member 121 corresponds to the adjacent sloping edge frame members of the pitched roof sections 14, 15.
In die preferred embodiment, me bracket and link members of figure l ie are used to connect: (a) the side wall sections 8—11 to adjacent pitched roof sections 14, 15; and (b) side wall sections 8—11 to adjacent gable end walls 6, 7, ie. where the sections lie edge to edge in ormogonal or oblique planes. As depicted in figure l ie, me frame member 120 corresponds to the lower longitudinal edge frame members of the pitched roof sections and the frame member 121 corresponds to die top edge of an adjacent side wall section; or the frame member 120 corresponds to vertical edge frame members 110, 111 of the gable end walls 6, 7, and die frame member 121 corresponds to the adjacent vertical edge frame members of the side wall members. It will be noted from figure 8 that the pitched roof sections 14, 15 have a lower longitudinal edge frame member 128 which is presented at an angle to d e pitched roof panel to enable engagement with die top edge frame members of the side walls.
To ensure that parts of the engagement mechanisms cannot become lost, each link member 123, 125, 126 is retained on one of the adjacent sections by way of a wire link 130.
Preferably, each section edge 120, 121 includes at least two of the bracket and link members spaced apart along the edge, although more may be used if required.
It will be understood that a number of different engagement mechanisms may be used to connect adjacent sections of the building togedier. The preferred embodiments described in connection widi figure 11 have been specifically designed to avoid die use of any screws or bolts in the assembly of the building, since direaded portions of screws and bolts may evenmally become damaged dirough cross-direading or the like . In addition, die use of screws or bolts requires a greater time for assembly and disassembly and a greater degree of precision in aligning components. In the preferred embodiment, where link members become difficult to release from their respective brackets, the simple sliding action required may be effected widi die assistance of a hammer or the like. Referring now to figure 12, the disassembly and stowage of die portable building 1 will now be discussed in detail. The profile of the building 1 has been designed to offer significant advantages in me way die building components may be flat-packed for shipping.
The provision of a pitched roof has a number of advantages in providing greater protection from the weather and also provides greater head room in the centre of the building where it is often of most utility. However, pitched roofs have die disadvantage that me widdi of die pitched roof sections (ie. viewed from a gable end of the building) is necessarily greater than die half widdi of the building, not even allowing for overhang of the pitched roof sections over side walls. Thus, it is not normally possible to flat pack pitched roof sections in the same plane adjacent one anodier, and space is often wasted.
In die present invention, however, the provision of a bridge section 16 between the two opposing pitched roof sections 14, 15 serves two important purposes. Firstly, the pitched roof section widths wR are made to be less than or equal to half die widdi of the building base platform wB (figure 4) thus enabling die two pitched roof sections to be laid side by side (ie. in me same plane) when flat packing. The bridge section 16 also offers further advantages. Firstly, it provides a flat platform when the building is assembled onto which a water tank may readily be attached. Secondly, die relatively small sections 16 can be adapted to receive air conditioning apparams in me form of air scrubbers or the like, particularly where the buildings are being used for military purposes or can be readily replaced widi sections 16 incorporating me appropriate hardware.
With further reference to figure 1, each base platform section 3, 4 includes a pair of leg sockets 140, 141 on each side of die platform section. These each receive a corresponding leg 142 for die purposes of giving me building ground clearance and levelling adjustment for uneven ground. The legs 142 may be height adjustable in leg sockets 140, 141 using suitable known memods.
When disassembling me building, die reverse operation to that described in connection widi assembly is carried out. For stowage into a flat pack 200, a first base platform section 4 is used as die package base. Note diat figure 12a shows the package 200 from the side of die base platform section 4 and figure 12b shows the package 200 from the front of the base section 4. Two side wall sections 8, 10 are then placed side by side on die base platform 4 with die panel 20 facing downwards and framework 30 facing upwards. The two gable end walls 6, 7 are then placed one on top of die odier, panel 20 facing panel 20 and in die same orientation, on top of die side wall sections 8, 10. The two further side wall sections 9, 11 are then placed over the top of die gable end 7 widi die framework 31 facing downwards. It will therefore be observed diat die two gable ends 6, 7 leave two triangular voids 201, 202 which are used for a storage box 203 and a heating / cooking stove 204. It is noted diat die voids 201 , 202 are somewhat thicker than twice me diickness of the gable end sections 6, 7, because die voids 201 , 202 also effectively include die diickness of die frameworks 30 of the side wall sections 8—11 above and below.
On top of die side wall sections 9, 11 are laid die four roof sections
14, 15, with frameworks 32 face to face, and on top of tiiose is laid die odier base platform section 3, skids downward. The depdi of die skids 70, 71 , 72 leaves a cavity into which is installed die two bridge sections 16, two verandah sections 206 to be described later, and guttering and downpipes 207 for rainwater collection. The three probes 73, 74, 75 may be locked inside skids 70, 71 , 72 of the base platform section 3.
The flat-pack 200 so formed is held togedier by die use of some of me levelling legs 142 which can be located into respective sockets 140, 141 of die two base platform sections and locked into place.
For transportation of the disassembled buildings, multiple flat-packs may be stacked together using a set of stacking legs 210, 211, 212 which have fingers 214, 215, 216 which engage with successive skid ends in me stack. The same pin mechanisms which lock the probes into place within the skids when die building is assembled may be used to lock the stacking legs 210—212 into the skid ends. In die presently preferred embodiment, four of die disassembled and flat-packed buildings 200 may be stacked in the same volume as mat occupied by one assembled building.
The buddings are then readUy transportable by lorry or aircraft in stacks without needing containerization, further reducing die cost of transport.
Also widi reference to figure 13, to enable adjustment in the position of me assembled buildings, and to ease die initial setting up of die base platform sections, the base platform sections may be provided widi lifting sockets 250 which are coupled to die outer edges of outer skids 70, 72, 78, 80, each of which includes a slot 251 widi a wide access from below which is adapted to receive a handle 252 having a collar 253 which engages behind die slot 252 as indicated in dashed outline on figure 13b. An alternative configuration of lifting sockets is depicted in figure 6c. Wiύ further reference to figure 1, figure 6c and figure 12, the buddings may be provided widi verandah floor sections 206 which are supported at eidier end of the building on support plates 260 which can be inserted into the ends of die various skids 70, 71 , 72, 78, 79, 80.
It will be understood diat die sealing of lateral joins between the adjacent pitched roof sections and side wall sections can be accomplished by die use of die tongue and groove profiles of the panels 20. Sealing of corner joins, eg. between gable end walls and side wall sections or pitched roof sections, and between pitched roof sections and side wall sections, can be accomplished by overlapping joins and or die provision of flashing material.
Guttering and rainwater collection hardware can be affixed to die pitched roof edges in customary manner.
From the foregoing description, it wdl be apparent that die cross- sectional profile of tihe building sections used offers a convenient, highly compactible portable building in which the side walls, gable end walls, base platform sections and roof sections, when assembled, provide a budding cross-sectional widdi w, side wall height hs not exceeding 0.5w, and pitched roof whose maximum height hM exceeds 0.6w (in the preferred embodiment = approximately 0.75w), and an overall length / approximately equal to 2hM; whose side walls, gable ends and roof sections can be stacked between two halves of die base platform to be contained wimin a volume defined by approximately w x 111 x less than 0.3

Claims

1. A portable building comprising: a base platform; side walls adapted to releasably engage with die base platform along the sides diereof; gable end walls adapted to releasably engage with die base platform across the widdi thereof; a pair of pitched roof sections each having a widdi which does not exceed half the widtti of die base platform; and a bridge section adapted to couple die pair of pitched roof sections together.
2. A portable budding according to claim 1 in which die bridge section has a widdi such diat die overall widdi of assembled roof is approximately equal to die widdi of die base platform.
3. A portable budding according to claim 2 in which me height of the side walls is selected not to exceed half of die widdi of die base platform.
4. A portable building according to claim 1, claim 2 or claim 3 in which the base platform comprises at least two sections of substantially equal widdi adapted to be connected togedier to extend die lengdi of die base platform.
5. A portable building according to claim 4 in which me base platform sections each include a plurality of longitudinal skids each adapted to receive a part of a probe, corresponding skids of adjacent sections of die base platform each receiving a part of one probe.
6. A portable budding according to claim 5 in which e base platform sections each include at least tihree skids, and in which me probes are adapted to engage widi die skids of one base platform section such mat mey each project longitudinally from the section a different distance.
7. A portable budding according to claim 6 in which the probe of the centre-most skid extends furthest longitudinally.
8. A portable budding according to claim 4 in which each base platform includes a plurality of leg post sockets and a plurality of corresponding leg posts, each socket and leg post adapted to enable variation in the height of the base platform from the ground on which it lies when die budding is assembled, and further adapted to lock two base platform sections togemer when the sections are stacked one over the odier when die budding is disassembled.
9. A portable budding according to claim 8 comprising two base platform sections, two gable end walls, four side wall sections, four pitched roof sections and two bridge sections in which all me disassembled budding components may be stacked onto one base platform section and covered widi die odier base platform section, the set of disassembled components being locked togedier by die leg posts engaging with respective sockets in bom base platform sections.
10. A portable budding according to any preceding claim in which die side wall sections, gable end walls and roof sections are formed from panels of insulation material mounted onto a framework.
11. A portable budding according to claim 10 in which die panels of insulation material are metal- or plastic-skinned polyurethane foam.
12. A portable building according to claim 10 or claim 11 in which the panels of insulation material are coupled to dieir respective framework by adhesive.
13. A portable budding according to claim 1 in which each side wall includes, on a lower edge diereof, means for engaging with die base platform by sliding in a horizontal plane.
14. A portable budding according to claim 13 in which each gable end wall includes, on a lower edge diereof, means for engaging the base platform only in a vertical direction.
15. A portable budding according to claim 14 in which each gable end includes, on a vertical edge diereof, means for engaging an adjacent side wall.
16. A portable budding according to claim 14 in which each side wall includes, on each vertical edge diereof, means for engaging an adjacent side wall or an adjacent gable end.
17. A portable building according to claim 14 in which each pitched roof section includes, on a horizontal edge diereof, means for engaging an adjacent side wall.
18. A portable building according to claim 14 in which each pitched roof section includes, on each sloping edge diereof, means for engaging an adjacent gable end wall or an adjacent pitched roof section.
19. A portable budding according to claim 17 or claim 18 in which said respective means for engaging each include no parts detachable from their respective side wall or gable end.
20. A portable budding according to claim 1 in which said bridge section is adapted to provide a flat roof section between opposing pitched roof sections.
21. A portable budding according to claim 20 in which said bridge section includes means for supporting a water tank.
22. A portable budding according to claim 20 in which said bridge section includes means for incorporating an air conditioning, air processing or air scrubbing system for delivery of air into the budding.
23. A portable budding according to claim 10 in which the framework of the gable end walls includes means for receiving one of a door unit, a window unit, or a connecting tunnel.
24. A portable building according to claim 5 in which the base platform includes a skid adjacent to each longitudinal edge, die skids including handle engaging means for temporarily coupling lifting handles to the sides of die base platform.
25. A portable budding according to any one of claim 5 to claim 9 further including means adapted to engage widi skids of die base platform and simultaneously to engage wim skids of one or more further portable buddings stacked on top of the first budding when all said buddings are disassembled and flat-packed, to thereby hold die buildings together for transportation.
26. A portable budding comprising side walls, gable end walls, base platform and roof sections which, when assembled, has a cross-sectional: widdi w, side wall height hs not exceeding 0.5w, and pitched roof whose maximum height hM exceeds 0.6w, and an overall length / approximately equal to 2hM; whose side walls, gable ends and roof sections can be stacked between two halves of the base platform to be contained widiin a volume defined by approximately w x //2 x ( < 0.3/zM).
27. A portable budding substantially as described herein widi reference to the accompanying drawings.
PCT/GB1998/000969 1997-04-01 1998-04-01 Portable flat-pack building WO1998044211A1 (en)

Priority Applications (3)

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NZ338035A NZ338035A (en) 1997-04-01 1998-04-01 Portable flat-pack building
EP98914956A EP0972117A1 (en) 1997-04-01 1998-04-01 Portable flat-pack building
AU69259/98A AU6925998A (en) 1997-04-01 1998-04-01 Portable flat-pack building

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GBGB9706552.8A GB9706552D0 (en) 1997-04-01 1997-04-01 Portable flat-pack building
GB9706552.8 1997-04-01

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ZA (1) ZA982708B (en)

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WO2004106656A1 (en) * 2003-05-30 2004-12-09 David Macbeth Macwatt Prefabricated portable flat pack building
WO2004106657A1 (en) * 2003-05-30 2004-12-09 David Macbeth Macwatt System and method for assembling prefabricated portable flat pack building
WO2008095474A2 (en) 2007-02-07 2008-08-14 Hans Wilhelm Meyer Building material
FR2942483A1 (en) * 2009-02-24 2010-08-27 Bernard Dauguet Advanced rigid and insulating structure forming method for mobile home construction, involves assembling panels to form walls and ceiling, where each panel is formed of trays juxtaposed on face on which frame is fixed to stiffen assembly

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SE535637C2 (en) * 2010-07-08 2012-10-23 Brod N Bengt-Inge Mobile house with height adjustable feet and floor with an upper and lower layer

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WO2004106656A1 (en) * 2003-05-30 2004-12-09 David Macbeth Macwatt Prefabricated portable flat pack building
WO2004106657A1 (en) * 2003-05-30 2004-12-09 David Macbeth Macwatt System and method for assembling prefabricated portable flat pack building
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FR2942483A1 (en) * 2009-02-24 2010-08-27 Bernard Dauguet Advanced rigid and insulating structure forming method for mobile home construction, involves assembling panels to form walls and ceiling, where each panel is formed of trays juxtaposed on face on which frame is fixed to stiffen assembly

Also Published As

Publication number Publication date
ZA982708B (en) 1999-09-20
EP0972117A1 (en) 2000-01-19
GB9706552D0 (en) 1997-05-21
AU6925998A (en) 1998-10-22
NZ338035A (en) 2001-03-30

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