U.S. patent application number 12/621875 was filed with the patent office on 2010-03-18 for transportable building.
This patent application is currently assigned to Prebuilt Pty Ltd's. Invention is credited to DONALD STEWART NAPIER.
Application Number | 20100064600 12/621875 |
Document ID | / |
Family ID | 29585028 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100064600 |
Kind Code |
A1 |
NAPIER; DONALD STEWART |
March 18, 2010 |
TRANSPORTABLE BUILDING
Abstract
A transportable building system including at least partially
erecting a building, transporting the at least partially erected
building on its side to a building location, locating the at least
partially erected building on a support at the building location,
and orientating the at least partially erected building so that it
is correctly orientated relative to its support. Further disclosed
is a transportable building, including a first structural
component, a second structural component and a hinge coupling the
first and second structural components whereby the second
structural component is pivotable between a folded position and an
unfolded erected position of the building. The hinge is
reconfigurable to allow the second structural component to be
relatively displaced away from the first structural component in
the unfolded erected position of the second structural
component.
Inventors: |
NAPIER; DONALD STEWART;
(Surrey Hills, AU) |
Correspondence
Address: |
WOLF GREENFIELD & SACKS, P.C.
600 ATLANTIC AVENUE
BOSTON
MA
02210-2206
US
|
Assignee: |
Prebuilt Pty Ltd's
Kilsyth
AU
|
Family ID: |
29585028 |
Appl. No.: |
12/621875 |
Filed: |
November 19, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10515790 |
Mar 13, 2006 |
7631460 |
|
|
PCT/AU2003/000658 |
May 29, 2003 |
|
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|
12621875 |
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Current U.S.
Class: |
52/79.5 |
Current CPC
Class: |
Y10T 16/5474 20150115;
E04B 1/3442 20130101 |
Class at
Publication: |
52/79.5 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A transportable building system, including: at least partially
erecting a building to form a box structure including a floor panel
and an internal wall panel about an enclosed space; orientating the
box structure to a position on its side; transporting the box
structure on its side to a building location; re-orientating the
box structure at the building location to locate the at least
partially erected building on a support at the building location so
that it is correctly orientated relative to its support; and
hingedly re-positioning an extension floor panel from a retracted
location parallel to said internal wall panel to an unretracted
location that increases the floor area provided by said floor panel
of the box structure.
2. A system according to claim 1, wherein the step of
re-orientating the at least partially erected building so that it
is correctly orientated relative to its support is carried out
before the step of locating the at least partially erected building
on the support at the building location.
3. A system according to claim 1, wherein the step of
re-orientating the at least partially erected building so that it
is correctly orientated relative to its support is carried out
after the step of locating the at least partially erected building
on the support at the building location.
4. A system according to claim 1, wherein the step of
re-orientating the at least partially erected building so that it
is correctly orientated relative to its support is carried out
substantially simultaneously with the step of locating the at least
partially erected building on the support at the building
location.
5. A system according to claim 1, wherein the at least partially
erected building is, while transported on its side, within width
and length dimensional limits for unescorted transport at any time
of day or night.
6. A system according to claim 5, wherein the at least partially
erected building has, while transported on its side, the width
dimensions of an international standard cargo shipping container
and includes a load-bearing frame and floor, walls and roof
panels.
7. A system according to claim 1, further including completing
erection of the building at the building location.
8. A system according to claim 7, wherein completing erection
includes unfolding out pre-constructed components of the building
including said extension floor panel.
9. A system according to claim 8, wherein said folded out
components are or include panels.
10. A system according to claim 8, wherein said building includes:
a first structural component; a second structural component; and
hinge means coupling said first and second structural components
whereby the second structural component is pivotable between a
folded position and an unfolded erected position of said building;
and wherein said hinge means is reconfigured to allow said second
structural component to be relatively displaced away from said
first structural component in said unfolded erected position of the
second structural component.
11. A system according to claim 10, wherein said first and second
structural components respectively comprise a floor component of
the at least partially erected building, and an extension floor
component.
12. A system according to claim 10, wherein said hinge means is
reconfigured by detachment of a link of said hinge means that
prevents said relative displacement of the second structural
component away from the first structural component.
13. A system according to claim 8, wherein said folded-out
components include a panel which is positioned in the erected
building as a verandah roof.
14. A system according to claim 13, wherein said panel positioned
as a verandah roof is nestable within an opening in a panel that
serves as a wall in the erected structure.
15. A system according to claim 8, including: folding out a wall
component; repositioning a second roof component so that it is at
least in part supported by said folded-out wall component, and lies
with an edge opposed to an edge of a first roof component; jointly
raising said edges of said roof components to a position defining a
roof-line ridge; and fixing said roof components at said position
defining a roof-line ridge.
16. A system according to claim 8, wherein said building includes a
plurality of wall components and roof means supported thereby, and
wherein said roof means includes: a first roof component that is
supported by said wall components during transport as an outer roof
component, and is displaced at said building location to provide a
roof for a folded-out part of the building, and a second roof
component supported by said wall components relative to said first
roof component to define a storage space during transport and a
rooftop zone on said displacement of the first roof component
17. A system according to claim 9, wherein further panels are
attached after said unfolding out of pre-constructed
components.
18. A system according to claim 17, wherein said further panels
include end walls.
19. A system according to claim 8, wherein said unfolding out of
pre-constructed components includes hingedly re-positioning a wall
panel from a retracted location parallel to said extension floor
panel in its unretracted location, to an upstanding location in
which it forms an external wall of the building.
20. A system according to claim 1, wherein plumbing is installed in
the partially erected building prior to transporting the box
structure to a building location.
21. A transportable building system, including: at least partially
erecting a building to form a box structure having a first floor
panel and an internal wall panel about an enclosed space;
transporting the box structure to a building location;
re-positioning an extension floor panel from a retracted location
during transport parallel to said internal wall panel to an
unretracted location that increases the floor area provided by said
first floor panel of the box structure, said extension floor panel
being displaced away from said first floor panel in said
unretracted location to form a gap therebetween, and filling said
gap with one or more floor panel inserts.
22. A transportable building system according to claim 21, wherein,
in said retracted location, said extension floor panel rests
upright on its edge on said first floor panel adjacent said
internal wall panel.
23. A transportable building, including: a box structure having a
first floor panel and an internal wall panel about an enclosed
space; an extension floor panel repositionable from a retracted
location during transport parallel to said internal wall panel to
an unretracted location that increases the floor area provided by
said first floor panel of the box structure, said extension floor
panel being displaced away from said first floor panel in said
unretracted location to form a gap therebetween; and one or more
floor panel inserts for filling said gap.
24. A transport building system according to claim 23, wherein, in
said retracted location, said extension floor panel rests upright
on its edge on said first floor panel adjacent said internal wall
panel.
Description
RELATED APPLICATIONS
[0001] This Application is a divisional application and claims the
benefit under 35 U.S.C. .sctn.120 of U.S. application Ser. No.
10/515,790, entitled "TRANSPORTABLE BUILDING" filed on Mar. 13,
2006, which is a national stage application of PCT/AU2003/000658
filed on May 29, 2003, each of which is herein incorporated by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to transportable buildings and
in particular to manufactured or pre-built housing.
BACKGROUND ART
[0003] It is known to pre-construct housing or commercial building
units at a base yard and subsequently transport them, either whole
or in two or more modules, to a client's allotment. Such buildings
are typically referred to as manufactured or pre-built housing and
for reference purposes will subsequently be referred to as
manufactured housing.
[0004] A principal constraint in the design of manufactured housing
is the strict dimensional limit set by road transport authorities
for ordinary unescorted loads. For example, while it is possible to
transport new manufactured homes in Australia having a width of 5
m, and a maximum height of 4.8 m, this typically requires expensive
permits, escorts and set routes, and regulations confine travel
times to daylight hours. In Australia and most countries, permits,
escorts and/or set routes, and restrictions on time of travel, can
be avoided only if the width load dimension is limited to 2.5 m and
the height load dimension is limited to 4.8 m, less the height of a
truck tray, which is normally 1.0 m.
[0005] If the manufactured housing is required to be transported
overseas, it must comply with International Shipping Organisation
(ISO) width dimensional limitations, which are more restrictive
than the above referenced domestic limitations. Thus, in Australia,
manufactured housing is such that the buildings or modules either
require over-dimensional permits and escorts, or are severely
restricted in their design and size by the width dimensional limits
Export housing, if attempted, is restricted by the ISO dimensional
limitations.
[0006] Aside from the issue of additional cost, access of
over-dimensional buildings to building sites is more restricted.
For example, over-dimensional buildings are typically not suitable
for dual occupancy sites, provision of granny flats or house
extensions, if the permanent location of the over-dimensional
building is not easily accessible due to access width restrictions.
Further, over-dimensional buildings are not generally suitable for
individual on-site housing, holiday housing, permanent housing such
as country, coastal and suburban retirement villages or mining town
accommodation.
[0007] Whether manufactured housing is designed beyond or within
the transport dimensional limits, a variety of design approaches
and features have been proposed to enhance the subsequent erected
building while minimising its dimensions during transit.
[0008] For example, Australian patent application 16482/95,
Australian patent 539799 and UK patent application 2257170 disclose
manufactured housing with hinged or extendible roof, verandah or
alcove elements. Australian patent application 71019/87 discloses a
demountable building assembly which is adaptable to form one or
more transportable containers. Building panels are stored in the
containers. U.S. Pat. No. 4,635,412 discloses an assembly which
folds to shipping container dimensions and includes multiple hinged
panels to form, for example, an enlarged floor area. Extension
floor panels hinge down on each side of the assembly and frame
assemblies in turn hinge up from the outer edges of the extension
floor panels. U.S. Pat. No. 5,237,784 discloses a transportable
container which has the form of a shipping container and includes
foldable walls which are designed to form an enlarged floor and
ceiling. Australian patent 720059 discloses an arrangement in which
a core of the house is transportable as a shipping container.
[0009] There is also manufactured housing that utilises shipping
containers. U.S. Pat. No. 4,891,919 discloses a shipping container
having hinge-down extension floor panels and hinge-up outer side
walls that are designed to unfold to form a house. International
patent publication WO 93/20297 discloses a shipping container that
forms a central zone of a house. Further zones are formed by
hinging out extension floors and roof extensions, and hinging up
outer side walls.
[0010] Housing a standard shipping container dimension of 2.1 m
ceiling height cannot be approved due to building regulation
requirements for a minimum or average ceiling height of 2.4 m in
all habitable rooms other than wet areas.
[0011] Transportable housing is also provided in the form of kit
housing. Like manufactured housing, some kit housing utilises
shipping containers, while other kit housing utilises purpose-built
structures which typically have the dimensions of shipping
containers. U.S. Pat. No. 5,447,000 discloses an open frame which
mimics a shipping container. The open frame structure can be
incorporated into a subsequent house or dismantled to provide
building components for the subsequent house
[0012] While kit housing is usually cheaper to purchase,
considerable time and greater effort and expertise is typically
required to erect a house using kit housing compared with
manufactured housing. Every component must be coded, often in
several languages, in an elaborate kit manual adding to the
complexity and difficulty of construction relative to manufactured
housing. Manufactured housing is therefore more suitable for
locations where building expenses are high, services such as power
or accommodation are non-existent, or building expertise is
limited. Furthermore, while warranties to protect the purchaser are
required by law in Australia and other countries such as USA,
United Kingdom and Canada for standard and manufactured housing,
they are not possible for kit housing, leaving the buyer with no
comeback or guarantee. A guarantee is required by lending
authorities, and therefore kit housing is difficult to fund with
loan money.
[0013] It is an object of the invention to provide improved
manufactured housing that is of optimum dimensions during transport
but enhanced size and form on erection. It is also preferable that
erection be achievable easily and quickly.
SUMMARY OF THE INVENTION
[0014] In a first aspect, the present invention provides a
transportable building system comprising: [0015] at least partially
erecting a building; [0016] transporting the at least partially
erected building on its side to a building location; locating the
at least partially erected building on a support at the building
location; and
[0017] orientating the at least partially erected building so that
it is correctly orientated relative to its support.
[0018] In its first aspect, the invention further provides a
transportable building which is at least partially erected and in
this condition arranged for transportation to a building location
on its side, and for re-orientation at the building location so
that it is correctly oriented relative to a support at the building
location.
[0019] It is emphasised that, in other aspects of the invention
later described, the transportable building is not necessarily
transported on its side.
[0020] The transported at least partially erected building
preferably forms a box structure about an enclosed space, more
preferably free of protrusions or extensions.
[0021] The step of orientating the at least partially erected
building so that it is correctly orientated relative to its support
can be carried out before, after or simultaneously with the step of
locating the at least partially erected building on the support at
the building location.
[0022] Preferably, the at least partially erected building is,
while transported on its side, within dimensional limits for
unescorted transport at any time of day or night.
[0023] In a preferred arrangement, the invention takes advantage of
the requirement that the minimum ceiling height within a building
(eg. 2.1 m in Australia for wet areas) is slightly less than the
standard international maximum width for road transport, 2.5 m.
Thus, with the partially erected building transported on its side,
the difference between these two standards can accommodate two
floor panels and two roof panels of total combined thickness no
greater than 400 mm (ie. average maximum per panel of 100 mm),
leaving a potential wet area height in excess of 21. m.
[0024] Once the transportable building is at the building location
it is required to be positioned on a support and, if necessary,
attached thereto. A partially erected transportable building is
then unfolded becoming fully erected. Completing erection can
involve unfolding components of the transportable building and/or
attachment of building components which may be transported within
the transported erected portion of the building. Unfolding of the
transportable building preferably involves pivoting of hinged
pre-constructed portions of the building, which may be panels and
may take the form of floor, wall and/or roof portions, from a
folded position to an unfolded, erected position.
[0025] These pivot mountings may in some instances be hinge
arrangements that allow relative displacement of the floor, wall or
roof portions in the unfolded position. This displacement may be
for widening the building in its erected state, or to enhance the
compactness of the transported erected portion of the building. The
floor, wall and roof portions may be panels which respectively form
part of a floor, wall and roof. Suitably, the panels are arranged
to unfold into locating relationship with adjacent panels or other
building components for attachment thereto to complete floors,
walls and roofs of the fully erected building. Some of the panels,
eg. roof panels in particular, may not be hinged and these unhinged
panels are preferably transported separately within or on top of
the transported erected portion of the building, for extraction and
installation during subsequent full erection of the building. Some
of the hinged panels may also be transported separately within the
building for subsequent hinged attachment to pre-erected panels of
the erected portion of the transportable building.
[0026] In a second aspect, the invention provides a transportable
building, including: [0027] a first structural component; [0028] a
second structural component; and [0029] hinge means coupling said
first and second structural component whereby the second component
is pivotable between a folded position and an unfolded erected
position of said building [0030] wherein said hinge means is
reconfigurable to allow said second component to be relatively
displaced away from said first component in said unfolded erected
position of the second component.
[0031] In this second aspect, the first and second structural
components may typically respectively be a floor component of the
at least partially erected building, and an extension floor
component.
[0032] The building may include a panel which is positionable (eg.
by being hingedly mounted) in the erected building as a verandah
roof. This panel is conveniently nestable within an opening in a
panel that serves as a wall in the. erected structure.
[0033] In a third aspect of the invention, there is provided a
method of erecting a building from a transported folded condition
having a plurality of wall components and a first roof component
supported thereby, including: [0034] folding out a wall component;
[0035] repositioning a second roof component so that it is at least
in part supported by said folded-out wall component, and lies with
an edge opposed to an edge of the first components; [0036] jointly
raising said edges of said roof components to a position defining a
roof-line ridge; and [0037] fixing said roof components at said
position defining a roof-line ridge.
[0038] By this method, it is possible to achieve a ceiling height
at the roof-line ridge up to 2 metres, allowing a mezzanine floor
thereunder to provide a habitable space.
[0039] Advantageously, in its third aspect, the invention includes
coupling said roof components by a plurality of link means that
space said roof components and serve as hinges during said raising
step.
[0040] Suitably, the at least partially erected building is
substantially fully erected, so that once the transportable
building is located and orientated at the building location, the
hinged or other panels simply have to be appropriately positioned
to fully erect it.
[0041] The transportable building is preferably substantially wired
prior to transportation. The electrical wiring is preferably
located within one or more panel cavities and enclosed therein by
removable cover plates. Wiring can then be completed in the process
of fully erecting the transportable building. The process of
locating, orientating and fully erecting (including completing
wiring) a typical 2 bedroom house which includes a mezzanine floor
should take two workmen less than one day to complete.
[0042] The transportable building may include structure that serves
as a mezzanine floor in the erected building. Advantageously, this
mezzanine floor is selectively set back from a wall in one or more
rooms and wall means, eg. a pivotably mounted wall portion, is
positionable to be upstanding from the set back edge to define a
partial cathedral ceiling. By this means, in the case where the
transported erected portion of the building is to be within the
aforementioned 2.5 m width limit, an average ceiling height for the
room greater than 2.1 m can be achieved while maintaining 2.1 m
under the mezzanine floor. A mezzanine height at the roof-line
ridge of 2 m can also be achieved, as discussed-earlier.
[0043] In a further aspect, the invention provides a transportable
building, including: [0044] a plurality of wall components and roof
means supported thereby, [0045] wherein said roof means includes:
[0046] a first roof component that is supported by said wall
components during transport as an outer roof component, and is
displaceable at a building location to provide a roof component for
a folded-out part of the building, and [0047] a second roof
component supported by said wall components relative to said first
roof component to define a storage space during transport and a
rooftop zone on said displacement of the first roof component.
[0048] The building components may comprise structural members or
elements. Suitably, the panels incorporate structural members of
the building such as walls or roof sections pre-made in panel form.
The structural members may comprise bearers, joists, studs, rafters
or other beams. Alternatively, structural members are transported
within the transportation container and incorporated into the fully
erected building at the building location. Structural elements
other than those incorporated into the panels are preferably
transported within the transported erected portion of the building
and may include items such as bolts, nails, screws, hold down
straps, structural or other timber or steel components which may be
required in addition to the hinged or other panels, to fully erect
the building, and items such as windows, sliding doors, kitchen
cupboards, structural extensions, and ridge or barge capping.
[0049] The transportable building may comprise any known building
components or techniques. For example, the floor of the
transportable building is preferably constructed using lightweight
steel or timber bearers and joists which, when appropriately
interconnected, provide joist flooring surfaces which lie in
substantially the same plane as adjacent surfaces of the bearers.
Such a bearer/joist arrangement reduces the overall height of the
building thereby increasing the height of rooms of the
transportable building. Examples of suitable such bearer/joist
arrangements include steel c-beam bearers, and corresponding steel
or timber joists, ends of these joists being arranged to fit into
internal channels of the c-beams. An alternative construction
utilises frames of welded or otherwise joined square hollow-section
steel beams.
[0050] Fixtures of the erected portion of the building may be
transported in their desired location. Alternatively, they are
contained within the transported partially erected building and
moved to their desired location for fixture thereto during the
process of fully erecting the building. Any necessary plumbing is
preferably installed, perhaps totally, as part of the process of
building the partially erected building.
[0051] While the partially erected building can initially be
orientated relative to its support so that it is correctly
orientated, rather than being on its side as it was during
transportation, it is preferred that it is initially orientated
relative to its support in the same manner as it was during
transportation. A floor portion of the transportable building,
which preferably forms a base of the transportation container, may
then be hingedly attached to its support. The transportable
building can then be unfolded from this sideways orientation by
pivoting the erected portion relative to the supported floor
portion until the erected portion is also supported via its
support.
[0052] The at least partially erected building preferably provides
a storage space in its lower region. The storage space is
preferably positioned adjacent the floor portion and is preferably
suitable for storing at least some of the building components which
are transported therein but do not form part of the erected portion
of the transportable building. The storage space is preferably
accessed by opening a hinged roof panel, facilitating removal of
long or large panels, or fittings such as cabinets, windows, doors,
and ridge or barge capping.
[0053] The transportable building may be arranged for attachment to
another transportable building to form a building which is a
combination of two or more transportable buildings. Alternatively,
the transportable building may be arranged to attach to a permanent
building to extend it.
[0054] The transportable building preferably comprises lifting
means to be engaged by a crane for moving it onto and off the
transportation vehicle, and if necessary, for manoeuvring it to the
correct orientation or upright position in the process of fully
erecting the building. The lifting means may comprise lugs or
forklift pockets or projecting attachment brackets. In remote
areas, where it is difficult to use or obtain cranes, it is
possible to manoeuvre the partially erected building over the
stumps and lower the building with jacks. A lightweight truck crane
can then lift or lower the roof, wall and floor panels into
position.
[0055] The transportable building may be, for example, a
transportable house or other dwelling, shelter, commercial
building, or shed.
[0056] Suitably, the transported partially erected building has
dimensions, eg. width dimensions, of an international standard
cargo shipping container and includes a load-bearing frame and
floor, walls and roof panels. The transported partially erected
building may have the cast steel corner fittings, or similar,
typical of an international standard cargo shipping it which the
container can be stacked on other similar containers for shipping
or storage.
[0057] By international standard cargo shipping container is meant
a container that meets International Shipping Organisation (ISO)
requirements for the International Convention for Safe Containers
(CSC) and the American Bureau of Shipping (ABS). These standards
include requirements for the size and strength of containers;
suitable sizes for the present purpose would be those referred to
as 20 ft and 40 ft containers.
[0058] For additional structural stability the fully erected
building may be fastened down to concrete pads or footings,
including where desired, fastenings such as, for example, cyclonic
tie-down rods, to additionally anchor the lower corner fittings to
the pads or footings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The invention will now be further described, by way of
example only, with reference to the accompanying drawings, in
which:
[0060] FIG. 1 is a perspective view of a transportable house
according to an embodiment of the invention, positioned on a
trailer for transport to a building location;
[0061] FIG. 2 is a cross-sectional view of the transportable house
in the on-trailer position of FIG. 1;
[0062] FIG. 3 is a composite view of the transportable house shown
of FIG. 1 being lifted off the trailer by a crane, re-oriented and
placed in foundation stumps in its final position;
[0063] FIG. 4 is a sequence of diagrams A to E showing the
principal steps in opening up the house, supported on stumps, to
its enlarged condition;
[0064] FIG. 5 is a perspective view of the enlarged house supported
by stumps in its final position, between diagram D and E in FIG. 4,
prior to fitting the ridge capping;
[0065] FIGS. 6 and 7 are a vertical cross-sectional view and a plan
view respectively of the hinging arrangement that couples the two
main roof panels;
[0066] FIGS. 8 and 9 are respective front and side elevational
views showing the form and movement of the hinging arrangement that
supports the extension floor panel;
[0067] FIG. 10 is a cross-sectional view of the enlarged house,
depicting the verandah and the hinged mounting of a side panel for
the mezzanine floor;
[0068] FIG. 11 is a side elevational view of the verandah
arrangement, with a hinge-up roof extension; and
[0069] FIG. 12 is a cross-sectional view of an alternative
embodiment that uses separate roof segments without a conventional
gable ridge, and has a parapet at one or both ends of the
house.
EMBODIMENTS OF THE INVENTION
[0070] Referring to FIGS. 1 and 2, the transportable house 6, in
its folded configuration on its side on a trailer 10, generally
comprises an erected generally rectangular unit having the
appearance and form of a box structure 8 about an enclosed space. A
window 12 is formed in end walls 14 of the transportable house 6
and windows 16 and 18 are formed in sidewall 20. A door 22 is
positioned approximately midway along the length of the sidewall
20. The transportable house 6 therefore comprises a pre-erected or
pre-assembled unit comprising the end walls 14 and an external side
wall 20. As will be explained in greater detail below, it also
comprises floor panels 40, 51, roof panels 56 and 58, an external
side wall 52, and an internal wall panel 54 (see FIG. 4) which is
positioned opposite the side wall 20.
[0071] Although the roof panels 56/58 are shown in a partially open
position in FIG. 1 for removal of materials from inside the
transportable house 6, they are closed during transport so that
they lie in a vertical plane. The floor panel 51 also lies in a
vertical plane, while side walls 20, 52 and internal wall panel 54
lie in a horizontal plane. The pre-erected portion of the
transportable house 6 is therefore positioned on trailer 10 on its
side so that the floor panel 51, roof panels 56/58, side walls 20,
52 and internal wall panel 54, as positioned on the trailer 10, lie
in planes perpendicular to planes they would normally lie in.
[0072] The pre-erected box structure of the transportable house 6
is approximately 2.5 m high and approximately 3.6 m wide. This is
how the structure is prepared at the manufacturer's factory site:
it is then re-orientated by crane and placed on its side on trailer
10 for transport to the purchaser's erecting site. This means that
in its sideways orientation, as positioned on a trailer 10, it is
3.6 m above the supporting surface of the trailer 10 and 2.5 m
wide. These measurements are within Australian and international
road transport dimensional limits for unescorted transport at any
time of day or night, ie. they are within the dimensional limits if
permits, escorts, set routes and travel time confined to daylight
hours are to be avoided. House 6 in the form of pre-erection box
structure 8 is thereby readily transportable from a factory site on
a truck trailer 10. It is built at such a site in its correctly
oriented position and then orientated onto its side onto trailer
10.
[0073] If it is preferred to avoid re-orientation, and the
aforementioned restrictions are acceptable, the box structure can
be transported in its "right side up" condition, with the floor 51
on the trailer.
[0074] The pre-erected portion and hinged or other panel support
structures of the transportable house are formed of welded
galvanised steel frames. However, as would be readily apparent to a
person skilled in the relevant art, they could also be formed of
corresponding timber structural members, or a combination of steel
and timber structural members. Likewise, the panels themselves can
be formed of steel or timber, or a combination thereof. The panels
could also comprise panels typically known as sandwich type
panels.
[0075] Other features of the transportable house 6 will be
described in the course of describing erection of the transportable
house 6 which essentially involves unfolding of hinged roofs, floor
and wall panels of the transportable house 6, and attachment of
other panels, structural members and elements that are contained
within the transportable house 6.
[0076] On arrival at the building location or erection site and
before the transportable house 6 is craned or forklifted off the
trailer 10, roof panels 56 and 58 may be pivoted upwardly via
hinges 24 and 26 and propped in an open position by suitable posts
28 (FIG. 1). With the roof panels 56 and 58 in this open position,
building components, such as ridge capping 59, which are required
to fully erect the transportable house 6, can be easily removed
from the inside 30 of the pre-erected box structure of
transportable house 6.
[0077] Once all of the removable building components have been
removed from the transportable house 6, a crane 32 is used to lift
the-transportable house 6 from the trailer 10 (FIGS. 2 and 3). As
shown in FIG. 4A the transportable house 6 can be lifted from the
trailer 10 and placed on three rows of stumps 36, 37 and 38
(located in pre-drilled concreted holes 39) so that a floor panel
51 is positioned on the stumps 36, 37 and 38. The floor panel 40 is
then subsequently pivoted downwardly to be supported by stumps 34,
to increase the floor area provided by floor panel 51 by
approximately 60%.
[0078] In an alternative delivery sequence, the transportable house
6 is lifted by the crane 32 and placed on the row of stumps 34 and
36 so that it is supported by them on its side and orientated the
same way as it was on the trailer 10. The floor 40 is left in place
and the rest of the structure is pivoted onto stumps 37, 38.
[0079] With the transportable house 6 supported on the stumps, it
is typically secured to those stumps by hold down straps (not
shown). One end of the straps is secured, via a bolt, to floor
panel 51 and the other ends of the straps are similarly attached,
via bolts, to the stumps.
[0080] Referring to FIG. 4B, with the transportable house 6
partially unfolded so that floors panels 40 and 51 are supported by
stumps 34-38, the partially unfolded transportable house 6
comprises external side walls 20 and 52, a pair of end walls (not
shown), an internal wall 54 and two roof panels 56 and 58. External
sidewall 52 is pivoted upwardly (FIG. 4B) from a position in which
it rests on floor panel 40, via hinges 62, which are positioned
along an outer longitudinal edge of floor panel 40. A roof is
erected by moving the outer roof panel 56 off roof panel 58 and
placing it, supported, on the top of raised wall panel 52. Roof
panels 56, 58 are then coupled at the centre line of the house by
hinge link configurations 68 (described further below). A crane
fitted to hinges 68 is employed to draw the centre edges 56a, 58a
of roof panels 56, 58 upwardly to form a roofline ridge fixed by
means of support beams 66 (FIGS. 4D, 5, 6 and 7). In this action,
panel 56 pivots upwardly about hinge pins such as bolts 57 at its
outer end, but panel 56 slides over the top of wall panel 52.
[0081] Hinge links 68 (FIGS. 6 and 7) allow lateral separation of
the opposed edges 56a, 58a of panels 56, 58 in the finished
structure and thereby facilitate a higher roof pitch and a wider
house. The higher roof pitch may accommodate a habitable mezzanine
space, which is acceptable accommodation in some types of
dwellings. The resultant gap 61 can be closed by suitable ridge
capping 59. Hinge links 68 comprise respective twin-plate arms 200
bolted to the opposite edges 56a, 58a (FIG. 4D) of roof panels
56,58, and hingedly coupled by hinge pin links 57: a crane hook can
be fitted at this point to draw up to the roof panels.
[0082] Non-hinged panels and building members and elements which
were removed from the inside 30 of the transportable house 6 are
then used to complete the erected house. Referring to FIG. 4, it
can be seen that the internal wall 54 is offset from a region where
floors panels 40 and 51 join. This positioning of the wall 54
enables a storage space 74 (see FIG. 4) to be provided in a lower
region (during transport) of the house 6 for storage of building
panels, members and elements.
[0083] The fully erected house 76 may include an optional verandah
102 formed of a roof extension 104 which is positioned
approximately centrally of the length of the house 76. The roof
extension 104 is supported, by its outer longitudinal edge 105, by
posts 107. Roof extension 104 is hingedly supported from a top
plate or top beam 103 of side wall 52 (FIG. 10) so that, on site,
it can be swung up and supported on posts 107. In its transport
position 104', roof extension 104 is nested in a corresponding
opening 105 in wall 52 (FIG. 11) and suspended from overhead beam
or top plate 103 of the wall by a sequence of hinges 101. After the
roof extension is raised into position 104 on site, opening 105 is
closed up by a preformed double window set 116 transported in
storage space 74 (FIG. 4B). In this way, verandah roof extension
104 is fixed to the original structure without increasing the width
or height of the box structure during transport (depending on the
orientation of transport).
[0084] FIGS. 8 and 9 illustrate a modification of the
above-described transportable house that incorporates an embodiment
of the second aspect of the invention, and achieves dimensional
advantages in the erected house without increasing the outer
dimensions of the transported house. This modification is depicted
in enlarged detail in FIGS. 8 and 9, and involves attaching floor
panel 40 to floor panel 51 in a triangular displacement hinge
configuration 62 so that floor panel 40 can be dropped over the
edge of floor panel 51 from a position standing upright on the
floor panel, and then displaced away from the floor panel. Hinge
configurations 62--one at each end of the house--comprise an
isosceles triangle of steel plate links 162, 163, 164 that form two
couplings between hinge axis 166, adjacent the side edge 168 of
floor panel 51, and a pivot mounting 170, on a right angular
bracket 172 fixed to the outside main face of extension floor panel
40. The shorter base link 162 of the triangle is one of these
couplings, long enough for the bottom edge face 41 of panel 40 to
rest on panel 51. The other coupling consists of links 163, 164 is
an initial V-connection 173 pinned together at 174.
[0085] Panel 40 pivots outwardly and downwardly about hinge axis
166 until it is flush and aligned with panel 40. Link 162 is now
detached and the V-connection 173 straightened out to move panel 40
away from panel 51. The resultant gap 175, which may, for example,
be 1 m or more across, is filled in by one or more floor panel
inserts 178. Links 163, 164 can be wholly removed, once floor
panels 40, 51 are fastened in place, so as not to interfere with
the attachment of cladding to the building.
[0086] It will be appreciated that hinged links 162, 163, 164,
allow lateral separation of floor 51 from panel 40 (FIGS. 8 and 9)
in the finished structure and thereby, together with roof hinge 68
(FIGS. 6 and 7), facilitate the widening of the living space.
[0087] Referring to FIGS. 5 and 11, the transportable house 6
includes a mezzanine floor 103 which is essentially identical in
floor area to the floor panel 51 which is positioned directly
below. The mezzanine floor 103 is accessible via a ladder (320).
Mezzanine floor 103 can alternatively be formed in a wide T-shape,
eg. to fully cover a centrally located bathroom but only the inner
half of bedrooms to either side. A hinged panel 304 can be swung
from a suspended position within each room to a raised position
304' in which it is fixed to roof panel 58. This creates a partial
cathedral ceiling 305 in each bedroom (thus increasing the average
ceiling height). This cathedral ceiling is facilitated by the
relatively steep pitch of roof panels 56, 58.
[0088] It will be seen that, if the bathroom has a ceiling height
of 2.1 m, the Australian minimum for wet areas, the total height
for transport, including the combined thickness of floor panels 51,
mezzanine floor 103 and roof panel 56 with ceiling height, can be
kept at 2.5 m or less, the maximum transportable width, ie. the
structure is within the width limit when transported on its side.
Moreover, because of cathedral ceiling 305, the average ceiling
height in the bedrooms such as room 306 can be 2.4 m or greater:
2.4 m is the Australian minimum for "habitable" areas. Still
further, all wiring can now be completed prior to transport as
lighting downlights can be installed under the mezzanine and not in
the folding roof sections.
[0089] FIG. 12 depicts an alternative embodiment, incorporating the
fourth aspect of the invention. Here, a gabled roof is not
attempted but instead side wall 20' and internal wall 54' extend
higher, are capped by a top panel 158 defining the box structure,
and are linked interiorly by a transverse fixed panel 155 below
panel 158. Floor panel 40', side wall 52', and verandah roof 104'
hinge into place as with the previous embodiment. In this case,
however, the roof is formed by lifting top panel 158 over the top
edge of wall 54', fixing it in a sloping position at 158' to wall
54' and resting it on the top of side wall 52'.
[0090] During transport, transverse fixed panel 155 defines,
between it and removable top panel 158, a storage space 300 (eg.
for panels as shown) that becomes an open skillion roof-top zone in
the fully erected house (sloping from rear to front in the
diagram), behind a parapet 153 defined by the upper parts of side
wall 20' and internal wall 54', and by end wall segments (not
shown).
* * * * *