U.S. patent application number 13/703085 was filed with the patent office on 2013-03-28 for building system and method.
The applicant listed for this patent is David Cain, Kenneth G. Trascher. Invention is credited to David Cain, Kenneth G. Trascher.
Application Number | 20130074424 13/703085 |
Document ID | / |
Family ID | 45497187 |
Filed Date | 2013-03-28 |
United States Patent
Application |
20130074424 |
Kind Code |
A1 |
Trascher; Kenneth G. ; et
al. |
March 28, 2013 |
BUILDING SYSTEM AND METHOD
Abstract
A system and method for construction of a building from
components, supplies and tools which are transported to the desired
building site in a shipping container. The building components
loaded and transported in the shipping container include
preassembled wall panels, ceiling panels, roof trusses, roof
panels, roof cladding sheets and wall cladding sheets. Each
preassembled component is sized so that no measuring or cutting of
same is required during construction at the building site, and each
component may be manually carried without the need for using a
lifting device.
Inventors: |
Trascher; Kenneth G.;
(Monroe, LA) ; Cain; David; (Mayfield Heights,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Trascher; Kenneth G.
Cain; David |
Monroe
Mayfield Heights |
LA
OH |
US
US |
|
|
Family ID: |
45497187 |
Appl. No.: |
13/703085 |
Filed: |
July 22, 2011 |
PCT Filed: |
July 22, 2011 |
PCT NO: |
PCT/US11/44960 |
371 Date: |
December 10, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61367143 |
Jul 23, 2010 |
|
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|
Current U.S.
Class: |
52/79.5 ;
52/745.2 |
Current CPC
Class: |
E04B 1/34384 20130101;
E04H 1/02 20130101; E04B 1/08 20130101 |
Class at
Publication: |
52/79.5 ;
52/745.2 |
International
Class: |
E04B 1/343 20060101
E04B001/343; E04H 1/02 20060101 E04H001/02 |
Claims
1. A system for the shipment of building components to a desired
building site, and the erection of a building at that site, the
system comprising: a. a shipping container housing all the
components of the system during transit to the building site; b.
preassembled side, front and rear wall panels for use in
constructing side, front and rear walls for the building, said wall
panels configured to be fastened together along their adjoining
edges when erected at the building site, wherein each wall panel
has an inner and an outer surface, and wherein each wall panel when
erected at the building site is configured to be supported by a
suitable foundation; c. preassembled ceiling panels for use in
constructing a ceiling for the building, wherein each ceiling panel
has an inner and an outer surface, and wherein each ceiling panel
when erected at the building site is configured to span the
distance between, and be supported by, the side walls of the
building; d. preassembled roof trusses configured to rest upon and
be supported by the ceiling panels, said roof trusses when erected
at the building site configured to extend the distance between the
side walls of the building; e. preassembled roof panels which, when
erected at the building site, are configured to rest upon and be
supported by roof trusses; f. precut sheets of roof cladding which,
when erected at the building site, are configured to be attached to
and supported by roof panels; and g. precut sheets of wall cladding
which, when erected at the building site, are configured to be
attached to and supported by wall panels.
2. The system of claim 1 wherein the preassembled wall panels,
ceiling panels, roof trusses, roof panels, roof cladding sheets and
wall cladding sheets are each sized so that no measuring or cutting
of the same is required during the construction of the building at
the desired site.
3. The system of claim 2 wherein: a. the loaded container further
comprises 6 wall panels and 8 ceiling panels; b. each wall panel
comprises four adjacent sheets of wall board, each wall board
measuring 4 feet wide and 8 feet high, and wherein each wall panel
is approximately 16 feet long and 8 feet high; and c. each ceiling
panel comprises 2 adjacent sheets of wall board, each wall board
measuring 4 feet wide and 8 feet long, and wherein each ceiling
panel is approximately 16.75 feet long and 4 feet wide.
4. The system of claim 2 wherein each building component as loaded
in the container weighs no more than 380 pounds.
5. The system of claim 2 wherein each building component as loaded
in the container can be carried by no more than 6 workers without
the need for using a lifting device.
6. The system of claim 2 wherein the container is a 20 foot long
metal container which complies with the specifications and
standards set by the International Organization for
Standardization.
7. The system of claim 2 wherein: a. the building as erected has 4
corners; b. each corner includes upper and lower sets of brackets;
and c. each set of brackets is comprised of an outside bracket and
an inside bracket which are configured to be fastened together by
bolts configured to pass through the building wall.
8. A system for the shipment of building components to a desired
building site and the erection of a building at that site from
those components without the need for any on-site measuring or
cutting of components, the building having a rectangular footprint
16 feet wide and 32 feet long, the system comprising: a. a 20-foot
long shipping container housing the components of the system during
transit to the site where the building is to be erected, wherein
the components comprise the following: b. preassembled, modular
wall panels for use in constructing walls for the building, wherein
the wall panels as shipped comprise a front wall panel and a rear
wall panel, each measuring approximately 16 feet long and 8 feet
high; 2 left side wall panels, each measuring approximately 16 feet
long and 8 feet high; and 2 right side wall panels, each measuring
approximately 16 feet long and 8 feet high; wherein each wall panel
when erected at the building site is configured to be supported by
a suitable foundation; wherein each wall panel as shipped is
comprised of 4 full sheets of wall board, each sheet being 4 feet
wide and 8 feet long, which are affixed to wall framing members;
and wherein each wall panel as shipped has a finished inner
surface, an outer surface and insulation covering said outer
surface; c. preassembled, modular ceiling panels for use in
constructing a ceiling for the building, wherein each ceiling panel
is approximately 16.75 feet in length such that in the constructed
building each ceiling panel is configured to span the distance
between and be supported by the left and right side walls; wherein
each ceiling panel is approximately 4 feet wide such that 8 ceiling
panels placed side-by-side will span the distance between the front
and rear walls; wherein each ceiling panel as shipped is comprised
of 2 full sheets of wall board, each sheet being 4 feet wide and 8
feet long, which are affixed to ceiling framing members; and
wherein each ceiling panel as shipped has a finished inner surface,
an outer surface, and insulation covering said outer surface; d.
preassembled, modular roof trusses for use in supporting roof
panels for the building, wherein each roof truss is triangularly
shaped and has 2 ends, a horizontal framing member extending
between the 2 ends and an apex extending above said horizontal
framing member; wherein each truss measures approximately 16.75
feet long from end to end such that when erected at the building
site each truss is configured to extend the distance between the
left and right side walls, said roof trusses configured to rest
upon and be supported by ceiling panels; and wherein a total of 9
trusses spaced 4 feet apart from each other are configured to
extend the distance between the front and rear walls when erected
at the building site; e. preassembled, modular roof panels
configured to be supported by roof trusses when erected at the
building site, wherein each erected roof panel has a length
sufficient to extend from at least the apex to an end of its
supporting roof trusses, and wherein 4 equal-sized roof panels
placed side-by-side are configured to extend the distance between
the front and rear walls; f. pre-cut sheets of roof cladding
configured to be attached to and supported by the roof panels when
erected at the building site, wherein each sheet of roof cladding
is at least as long as its supporting roof panel, and wherein
adjacent sheets of roof cladding are configured to cover the entire
roof of the building; and g. pre-cut sheets of wall cladding
configured to be attached to the outer surfaces of the wall panels
when erected at the building site, and wherein adjacent sheets of
wall cladding are configured to cover the entire walls except for
door openings, air conditioner openings and other wall openings
which accommodate other building accessories.
9. The system of claim 8 further comprising building tools and
supplies necessary for assembling the building components into a
finished building, said building tools and supplies loaded in and
shipped with the container, said building tools and supplies
comprising screws, screwdrivers, wiring, electrical outlets,
switches, light fixtures and insulation.
10. The system of claim 8 wherein no other building components,
tools and supplies are necessary to erect a finished building
except those that are loaded in and shipped with the container.
11. A system for the shipment of building components to a desired
building site, and the erection of a building at that site from
those components, the system comprising: a. a shipping container
housing all the components of the system during transit to the
building site; b. preassembled side, front and rear wall panels for
use in constructing side, front and rear walls for the building,
said wall panels fastened together along their adjoining edges when
erected at the building site; wherein each wall panel has an inner
and an outer surface, and wherein each wall panel when erected at
the building site is supported by a suitable foundation; c.
preassembled ceiling panels for use in constructing a ceiling for
the building, wherein each ceiling panel has an inner and an outer
surface, and wherein each ceiling panel when erected at the
building site spans the distance between, and is supported by, the
side walls of the building; d. preassembled roof trusses which,
when erected at the building site, rest upon and are supported by
the ceiling panels and extend the distance between the side walls
of the building; e. preassembled roof panels which, when erected at
the building site, rest upon and are supported by roof trusses; f.
precut sheets of roof cladding which, when erected at the building
site, are attached to and supported by roof panels; and g. precut
sheets of wall cladding which, when erected at the building site,
are attached to and supported by wall panels.
12. The system of claim 11 wherein: a. the building as erected at
the desired site has 4 corners; b. each corner includes upper and
lower sets of brackets; and c. each set of brackets is fastened
together by bolts passing through the building wall.
13. The system of claim 11 further comprising preassembled floor
panels which, when erected at the building site, are anchored to
the ground and provide support for the walls which are erected
thereon.
14. The system of claim 13 wherein each floor panel comprises 2
adjacent sheets of wall board, each wall board measuring 4 feet
wide and 8 feet long, and wherein each floor panel is at least 16
feet long and approximately 4 feet wide.
15. A method of constructing a building from components, supplies
and tools shipped to a desired building site, comprising the steps
of: a. loading into a shipping container all the components,
supplies and tools needed to construct the building, comprising
preassembled wall panels, ceiling panels, roof trusses, roof
panels, sheets of roof cladding and sheets of wall cladding; b.
transporting the loaded shipping container to the desired building
site; c. unloading the shipping container at the desired building
site; d. erecting front, rear and side walls for the building by
standing the wall panels up on a suitable foundation at the
building site, and fastening the wall panels together along their
adjacent edges to form the building perimeter; e. lifting the
ceiling panels in place such that they span the distance between
and are supported by the erect side walls of the building; f.
lifting the roof trusses in place such that they rest upon and are
supported by ceiling panels; g. lifting the roof panels in place
such that they rest upon and are supported by roof trusses; h.
attaching the sheets of roof cladding to the roof panels; and i.
attaching the sheets of wall cladding to the wall panels.
16. The method of claim 15 wherein the preassembled wall panels,
ceiling panels, roof trusses, roof panels, roof cladding sheets and
wall cladding sheets are each sized so that no measuring or cutting
of same is required during the construction of the building at the
desired building site.
17. The method of claim 15 wherein the preassembled wall panels,
ceiling panels, roof trusses, roof panels, roof cladding sheets and
wall cladding sheets are each sufficiently light to be carried and
installed by no more than 6 workers at the building site without
the need for any lifting device.
18. The method of claim 15 further comprising the steps of: a.
loading into the shipping container, prior to transporting it,
preassembled floor panels; b. erecting a floor for the building,
prior to erecting the building walls, by placing the floor panels
on ground support at the desired building site; and c. erecting the
walls on the floor panels, said floor panels providing a suitable
building foundation at the site.
Description
REFERENCE TO PRIOR APPLICATION
[0001] This application claims the benefit and priority of U.S.
Provisional Patent Application Ser. No. 61/367,143 filed on Jul.
23, 2010, which is hereby incorporated by reference in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a system and method for
construction of a building from components, supplies and tools
which are transported to the desired construction site in a
shipping container, thereby facilitating quick and efficient
building construction, especially in remote areas.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to a building system and
method for construction and use in locations and environments where
it is difficult, if not impossible, to procure adequate building
materials and skilled labor. Such locations include, without
limitation, areas which have been ravaged by war, storms and other
disasters (hereinafter "disaster areas"). In such disaster areas,
construction materials, tools and skilled labor are generally
unavailable, yet it is precisely in such areas where at least some
initial building is desperately needed so that the process of
recovery can begin.
[0004] The building system and method of the present invention are
a significant improvement over existing building systems used in
disaster areas. For example, in war-ravaged areas, the standard
military building system typically involves three stages or phases
for establishing a progressively more substantial presence at the
location. Phase 1 consists of a tent on natural dirt as a floor. In
phase 2 a wooden floor is built under the existing tent. In phase 3
a wooden shell is built over the tent, resulting in a shelter which
is prone to fire, rot, termites, decay and warpage. Such shelters
have a limited life expectancy and are uncomfortable to inhabit.
This staged process is due in part to the materials used, and the
considerable time and effort required, for the above described
standard military building.
[0005] By contrast, the building of the present invention can be
completely erected in a single process within a fraction of the
time, and resulting in a much more habitable and permanent
building, than is the case with the above described, three-stage,
standard military building. The present invention essentially
replaces all 3 phases of the standard disaster-area building system
with a semi-permanent structure which is fireproof, not subject to
decay, insects or warpage, and is much more habitable than said
standard system.
[0006] The preferred system of the present invention provides for
the use of metal framing members, fiber cement wall boards, and
metal wall and roof cladding, which are totally noncombustible and
are not subject to rot, termites, decay or warpage. This provides
significant advantages over traditional military building systems
involving the use of wood and other building materials at disaster
areas, which are prone to such problems. Moreover, the materials
for such traditional military building systems, including plywood
and wooden framing systems, are typically imported from North
America and drain the eco-system, whereas the materials used in the
present invention can be sourced worldwide without loss of timber
or associated damage to the eco-system.
[0007] As an alternative to such traditional military building
systems, the prior art includes so-called relocatable buildings
("RLBs") which are typically shipped via flat pack containers. An
advantage of the RLBs is that they can be shipped in a flat
configuration of 4 units. However, there are many disadvantages
associated with RLBs, including the following: they are limited in
size to 8 feet by 20 feet, which is not the standard size used by
the U S military; they are not rigid or semi-permanent; they are
fragile to impact and wind; and they have an undesirable flat roof.
Moreover, manufacturers of the RLBs are usually located outside the
United States, such that the electrical wiring and related
electrical components provided with RLBs must be replaced with
110/220v for use by U.S. customers such as the U.S. military.
Additionally, a crane or other lifting device is required to help
assemble RLBs, and the RLB components are not fireproof.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides a building system and related
method for rapid deployment via a shipping container to a disaster
area where the building can be erected in minimal time with minimal
labor. Packed within the shipping container are all of the
necessary building components, including modular wall and ceiling
panels, roof trusses, roof panels, and wall and roof cladding. Also
packed within the shipping container are all of the building
materials, tools, fasteners and supplies needed to erect the
building. Upon arrival of the container at the disaster area, its
contents can be expeditiously unloaded and the building can be
constructed with a minimum of effort, time and labor, with minimal
need for measuring or cutting of any materials, and without the
need for a crane or other lifting device.
[0009] In the preferred embodiment of the present invention, the
wall and ceiling panels are comprised of standard-sized, full
width--full height sheets of cement fiber board, measuring 4 feet
by 8 feet (1220 mm.times.2440 mm), so that there is no cutting or
fitting required on site for said panels. By not having any panel
waste materials, the net payload to be transported via the
container to the disaster area can be kept to the bare minimum, and
all the transported panel components can be incorporated into the
work. Similarly, there is no cutting, fitting or waste material
involved in connection with the roof trusses and roof panels. No
waste material means no debris to dispose of, and site erection is
eco-friendly. The present invention provides for a structure having
the same standard size as existing building systems used by the
U.S. military in disaster areas, i.e., 16 feet wide and 32 feet
long, with an 8 foot ceiling (4870 mm.times.9756 mm.times.2440 mm).
To simplify erection in disaster areas where the instant invention
may be deployed, and where skilled craftsmen are likely
unavailable, the major building components of the invention are
preassembled and modularized, requiring no measuring or
cutting.
[0010] The preassembled and modularized building components of the
present invention include wall panels, ceiling panels, roof trusses
and roof panels, each of which is light enough to be lifted
manually and small enough to be fitted into a 20-foot shipping
container. To further simplify erection of the building in
accordance with the preferred system and method of the present
invention, there are provided 6 identical-sized wall panels, 8
identical ceiling panels, 9 identical roof trusses and 8 identical
roof panels.
[0011] The preassembled wall and ceiling panels of the present
invention preferably have a finished inner surface which is faced
with fiber cement wall board. The outer surface of the wall and
ceiling panels may be equipped with electrical wiring, plumbing,
telecommunication cables and other accessories, and are covered
with insulation.
[0012] Upon arrival of the shipping container at the desired
building site, the wall panels are removed from the container,
stood erect at the building site and connected to one another.
Ceiling panels that were also shipped in the container are then
lifted in place, spanning and supported by the wall panels, thereby
creating a building interior envelope within a matter of hours.
[0013] Roof trusses and roof panels, also shipped in the container,
are then lifted in place, the roof trusses supported by the ceiling
panels and the roof panels supported by the roof trusses. The roof
panels and wall panels are then faced with pre-cut metal cladding,
also shipped in the container, resulting in a walled building under
roof in minimal time without the need for any measuring or any
cutting, and without the need for any crane or other lifting
device. The preferred building of the present invention, containing
512 square feet and having a standard military configuration 16
feet wide and 32 feet long, can be erected in approximately 10
hours by a 6-person team having minimal building skills. This is
much less time, involving much fewer people with much less skill,
than is required with existing building systems deployed in
disaster areas.
[0014] The building of the present invention may be erected on and
anchored to an existing concrete slab or other existing foundation
at the building site. Alternatively, the shipping container of the
present invention may include preassembled floor panels having a
finished inner surface faced with fiber cement wall boards. The
floor panels may be anchored to the ground at the desired building
site, and the building may erected on the floor panels. The
building may be fastened and secured on all 4 exterior and interior
corners with metal "L" brackets which are through-bolted.
[0015] In summary, the preferred building system of the present
invention provides the following features and benefits:
[0016] 1. Simple erection of building components, including modular
wall panels, ceiling panels, roof trusses and roof panels,
facilitating work by soldiers and others who may have minimal
construction training and/or experience.
[0017] 2. Indefinite lifespan of the building.
[0018] 3. The entire building system, including components,
materials and tools, fits into one shipping container.
[0019] 4. Rapid erection, multi-purpose use of building.
[0020] 5. Snow, wind and earthquake resistant.
[0021] 6. Made of all fire-resistant materials.
[0022] 7. Will not rot, decay or warp, and is not subject to
termites or other insects.
[0023] 8. Building can be extended infinitely in length via
additional containers.
[0024] 9. Interior walls can easily be added.
[0025] 10. Complete system uses the above structure and adds
standing seam sheeting for exterior walls and root cement fire
board for interior wall, 1 hour fire rated steel door.
[0026] 11. Building site is without construction debris and is
ecologically friendly.
[0027] 12. The building can be rapidly erected at the desired site
with minimal need for measuring or cutting materials, and without
the use of cranes, forklifts or other lifting devices.
[0028] 13. The building of the present invention has a universal
flexibility in that it can be used as housing, offices, medical
clinic, classroom, latrines, mess halls and so forth.
BRIEF DESCRIPTION OF DRAWINGS
[0029] FIG. 1 is a perspective view of the preferred building of
the invention.
[0030] FIG. 2 is a perspective view of the preferred building of
the invention next to the container in which all of its components,
along with the necessary building materials and tools, were
shipped.
[0031] FIG. 3 is a top view of the container, absent its top,
showing the building components, materials and tools nested
therein.
[0032] FIG. 4 is a partial, perspective view of the inside of the
container depicted in FIG. 3.
[0033] FIG. 5 is a perspective view depicting the
erection-in-progress of the building walls in accordance with the
invention.
[0034] FIG. 6 is a side elevational view of the outer surface of a
preassembled modular wall panel, covered with insulation.
[0035] FIG. 7 is a side elevational view of the finished inner
surface of a preassembled modular wall panel.
[0036] FIG. 8 is a floor plan view of the building, i.e., a top
view of the preferred building of the invention absent its ceiling
panels, roof trusses, roof panels and roof cladding.
[0037] FIG. 9 is a partial, perspective view depicting the erection
of ceiling panels placed on and supported by walls of the
building.
[0038] FIG. 10 is a partial, perspective view depicting the
erection of ceiling panels placed on and supported by building
walls, with several roof trusses in place.
[0039] FIG. 11 is a partial, perspective view depicting the
building walls in place, ceiling panels supported by the building
walls, and roof trusses supported by the ceiling panels.
[0040] FIG. 12 is a side elevational view of a preassembled modular
roof truss in accordance with the preferred embodiment of the
invention.
[0041] FIG. 13 is a partial, perspective view depicting a
preassembled, modular roof panel being lifted in place, after the
building walls, ceiling panels and roof trusses have been
erected.
[0042] FIG. 14 is a top view of a preassembled, modular roof panel
in accordance with present invention.
[0043] FIG. 15 is a partial, perspective view depicting the
placement-in-progress of roof cladding on a roof panel in
accordance with the invention.
[0044] FIG. 16 is a perspective view of the building of the present
invention, nearing completion, with the wall-cladding not yet fully
complete.
[0045] FIG. 17 is a cross sectional view of the entire, completed
building, taken along lines 17-17 of FIG. 8.
[0046] FIG. 18 is a plan view of the outer surface of a
preassembled, modular ceiling panel without any insulation, showing
its framing members.
[0047] FIG. 19 is a plan view of the finished inner surface of a
preassembled, modular ceiling panel.
[0048] FIG. 20 is a perspective, fragmentary view of a building
corner in accordance with the invention, showing a set of
L-brackets in place, taken from FIG. 2 as shown.
[0049] FIG. 21 is a perspective view of a preassembled, modular
floor panel is accordance with the invention, with a portion of its
wall board cut away for purposes of illustration.
DETAILED DESCRIPTION
[0050] FIG. 1 generally depicts the finished building 10 of the
present invention in its preferred embodiment. FIG. 2 depicts
building 10 adjacent to shipping container 12 of the preferred
embodiment of the present invention. Container 12 is large enough
to accommodate, and is used to transport, all of the building
components, supplies and tools needed to construct the finished
building 10 at the desired building site.
[0051] Container 12 is preferably a 20-foot long metal container
which complies with the specifications and standards set by the
International Organization for Standardization, commonly referred
to as a 20-foot ISO shipping container. Container 12 can be shipped
by any number of transportation means, including truck, train,
boat, and air transport.
[0052] FIGS. 3 and 4 generally depict the building components,
supplies and tools loaded and nested inside container 12 in the
preferred embodiment of the invention. Container doors 14 are
closed during transport of the loaded container 12 to the desired
building site. Doors 14 are reopened when the container 12 has
reached the desired building location, so that the building
components, supplies and tools can be unloaded and the building can
be constructed.
[0053] The building components preferably include a plurality of
preassembled, modular wall panels 20, as best depicted in FIGS. 5,
6 and 7. In the preferred embodiment of the invention, each wall
panel 20 is approximately 16 feet long and 8 feet high, more
preferably 16'2'' by 8'0'', and fits comfortably inside a 20-foot
ISO container 12 as shown in FIGS. 3 and 4.
[0054] As depicted in FIG. 7, each wall panel 20 preferably
includes 4 full sheets of fiber cement wall board 22, each sheet 22
preferably being 4 feet wide, 8 feet long and 0.236 inches thick.
Each wall panel 20 is preferably preassembled, prior to being
loaded and shipped in container 12, by affixing 4 adjacent sheets
22 to wall framing members 24, as depicted in FIG. 6. Wall framing
members 24 are preferably comprised of metal studs having a
channel-shaped profile, said studs preferably having the following
dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches
(41 mm); and stud depth of 3.50 inches (89 mm)
[0055] In the preferred embodiment of the invention, each sheet of
wall board 22 is attached to framing members 24 by using clips 100,
commonly referred to as "omega clips." Omega clips 100 have a
profile somewhat similar to the Greek capital letter omega, said
profile providing a channel which accommodates the insertion
therein of an edge portion of sheet 22. Also known sometimes as
"hat omega" clips because their profile resembles that of a top
hat, omega clips 100 may be obtained through material suppliers
such as BAATCO (Burj Al Aaj Building Materials) located in Dubai.
The clip profile includes a flange which extends parallel to sheet
22. The flange can be provided with holes to accommodate screws
passing therethrough, said screws being used to attach the omega
clips 100 to their supporting frame members 24. As shown in FIG. 7,
omega clips 100 are preferably used along the perimeter edges of
sheets 22 which abut other sheets 22, but not along the perimeter
edges which form an angle with other surfaces such as the floor,
the ceiling or an intersecting wall.
[0056] As preassembled, each wall panel 20 has a finished inner
surface 26 and an outer surface 28, as best depicted in FIGS. 7 and
6. Wall framing members 24 are preferably provided with openings 23
along their lengths, as depicted in FIG. 5, to accommodate the
passage therethrough of electrical wiring, plumbing,
telecommunication cables and other conduits that may be run along
the outer surface 28 of the wall panel 20.
[0057] The outer surface 28 of preassembled wall panel 20 is
preferably covered with wall insulation 30, as shown in FIG. 6. A
preassembled wall panel 20 may also be provided with one or more
openings through one or more sheets 22 of wall board, suitable to
accommodate building accessories such as air conditioners, windows,
doors and electrical outlets. For example, as best depicted in
FIGS. 5-7, a wall panel 20 may have an opening 27 to accommodate an
air conditioner, an opening 29 to accommodate a door, and openings
25 to accommodate electrical outlets.
[0058] Each preassembled wall panel 20 preferably has a total
weight of approximately 300 pounds, sufficiently light to be
carried by 6 workers without the need for using a crane or other
lifting device, as such devices are generally unavailable in remote
locations where the present invention may be deployed.
[0059] In the preferred embodiment of the invention, the loaded
container 12 includes a total of 6 wall panels 20 which are used to
form the walls of building 10, as shown in FIG. 5, as follows: one
16-foot long wall panel is used for the front wall 32 of the
building; another 16-foot long wall panel is used for the rear wall
34 of the building; two other 16-foot long wall panels, placed
side-by-side, are used for the left side wall 36 of the building;
and two other 16-foot long wall panels, placed side-by-side, are
used for the right side wall 38 of the building. As so configured
in the preferred embodiment of the invention, building 10 has a
rectangular footprint measuring 16 feet wide and 32 feet long,
which is the standard size and configuration favored by the U.S.
military, and can be used for buildings such as barracks, offices,
latrines, and mess halls.
[0060] It is understood that building 10 of the present invention
is not limited to a 16-foot by 32-foot rectangular configuration.
For example, each of the front, rear and side walls of building 10
may include any number of wall panels 20, placed side-by-side so as
to form a building having a desired width and length.
[0061] When the loaded container 12 arrives at the desired building
site, the preassembled wall panels 20 may be unloaded from the
container by soldiers or other workers, who carry the wall panels
to the site where the building is to be erected. The bottom of each
wall panel is placed on top of and is supported by a suitable
foundation for the building, for example an existing concrete slab.
Alternatively, as described in further detail later below, the wall
panels 20 may be placed on and supported by preassembled modular
floor panels 110, depicted in FIG. 21, which may be shipped in and
with container 12.
[0062] FIG. 5 depicts a typical wall erection for the preferred
building in accordance with the present invention. Wall panels 20
are erected by standing them up straight, with each of the inner
surfaces 26 facing and forming the building interior. As shown in
FIG. 5, rear wall 34 and right side wall 38 have already been stood
upright. To keep them standing upright during the construction
process, rear wall 34 and right side wall 38 are preferably
fastened together along their adjoining edges by the use of
suitable fastening means such as screws, which are sometimes
referred to in the industry as "grabber" screws (hereinafter
"screws"). Such fastening means are among the building components
transported in container 12 of the present invention.
[0063] FIG. 5 also shows the left side wall 36 in the process of
being stood up erect by workers. After the left side wall 36 is
stood erect, the adjoining edges of the left side wall 36 and the
rear wall 34 may be fastened together with suitable fastening means
such as screws.
[0064] The front wall 32, shown in FIG. 5 in the supine position,
is similarly stood up like the other walls. The adjoining edges of
the erect front wall 32 and the erect side walls 36 and 38 may be
fastened together with suitable fastening means such as screws,
similar to the manner in which the adjoining edges of the rear wall
34 and the side walls 36 and 38 may be fastened together.
[0065] The perimeter of the building is established once all the
wall panels shown in FIG. 5 have been stood erect. This can be
accomplished in the preferred embodiment of the present invention
in approximately 2 hours by 6 workers, without the need for any
measuring or cutting of any materials, and without the need for any
crane or other lifting device. If desired, interior wall panels may
be loaded and shipped with container 12 to the building site, where
they may be installed within the building interior to create
interior spaces of various sizes and shapes. For example, an
interior wall panel 8 feet high and 16 feet in length, with both
sides finished with fiber cement wall board and with an opening to
accommodate an inner door, may be used in the middle of the
building to create 2 interior offices within the building, each
office measuring 16 feet by 16 feet.
[0066] The building components of the preferred embodiment of the
invention also include a plurality of preassembled, modular ceiling
panels 40, as best depicted in FIGS. 9, 10, 18 and 19, for use in
constructing a ceiling for building 10. In the preferred embodiment
of the invention, each ceiling panel 40 measures approximately
16.75 feet long and 4 feet wide, more preferably 16'9.26'' by
4'0.55'', and fits comfortably inside a 20-foot ISO container 12 as
shown in FIG. 4.
[0067] As best depicted in FIG. 9, each ceiling panel 40 preferably
includes 2 full sheets of fiber cement wall board 42, each sheet 42
preferably being 4 feet wide, 8 feet long and 0.236 inches thick.
Each ceiling panel 40 is preferably preassembled, prior to being
loaded and shipped in container 12, by affixing 2 adjacent sheets
42 to ceiling framing members 44, depicted in FIG. 18. Ceiling
framing members 44 are preferably comprised of metal studs having a
channel-shaped profile, said studs preferably having the following
dimensions: metal thickness of 0.75 mm; stud width of 1.61 inches
(41 mm); and stud depth of 3.50 inches (89 mm)
[0068] In the preferred embodiment of the invention, each sheet of
wall board 42 is attached to framing members 44 by use of omega
clips 100, similar to the way that each sheet of wall board 22 is
attached to framing members 22 as described above. Omega clips 100
are preferably used along the perimeter edges of sheets 42 which
abut other sheets 42, but not along the perimeter edges which form
an angle with other surfaces such as an intersecting wall.
[0069] As preassembled, each ceiling panel 40 has a finished inner
surface 46 and an outer surface 48. Ceiling framing members 44 may
be provided with openings along their lengths to accommodate the
passage therethrough of electrical wiring, plumbing,
telecommunication cables and other conduits that may be run along
the outer surface 48 of ceiling panel 40. The outer surface 48 of
preassembled ceiling panel 40 is preferably covered with ceiling
insulation 50, as depicted in FIG. 11.
[0070] A preassembled ceiling panel 40 may also be provided with
one or more openings through one or more sheets 42 of wall board,
suitable to accommodate building accessories such as light fixtures
and electrical outlets. Each preassembled ceiling panel 40
preferably has a total weight of approximately 165 pounds,
sufficiently light to be carried by 4 workers without the need for
using a crane or other lifting device, as such devices are
generally unavailable in remote locations where the present
invention may be deployed.
[0071] In the preferred embodiment of the invention, the loaded
container 12 includes a total of 8 ceiling panels 40, each ceiling
panel 40 measuring 4 feet wide by 16 feet long, which are used to
form the ceiling of building 10 having a rectangular footprint
measuring 16 feet wide and 32 feet long.
[0072] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration. Accordingly, if building 10 for example
has a width of 20 feet rather than 16 feet wide, the ceiling panels
40 will each have a corresponding length of at least approximately
20 feet, sufficient to span the distance between and rest upon the
side walls 36 and 38 of the building.
[0073] The preassembled ceiling panels 40 may be unloaded from
container 12 at the building site by soldiers or other workers who
carry the ceiling panels 40 from container 12 to the building site.
After the building walls have been erected, the ceiling panels 40
are then lifted in place by the workers, such that in the
constructed building each ceiling panel 40 spans the distance
between and is supported by the side walls 36 and 38, as depicted
in FIGS. 9 and 10, with the finished inner surface 46 of each
ceiling panel 40 facing downward and toward the inside of the
building. In the preferred embodiment of the invention, wherein
building 10 has a rectangular footprint measuring 16 feet wide and
32 feet long, 8 ceiling panels 40 placed side-by-side span the 32
foot distance between the front and rear walls 32 and 34 of the
building.
[0074] Adjacent ceiling panels 40 are preferably fastened together
along their adjoining edges by the use of suitable fastening means
such as screws. The ceiling panels 40 are also preferably fastened
to the side walls 36 and 38 and (for the ceiling panels adjacent to
the front and rear walls) to the front and rear walls 32 and 34 by
suitable fastening means such as screws. The fastening means for
ceiling panels 40 are among the building components loaded and
transported in container 12 of the present invention.
[0075] The 8 ceiling panels 40 in the preferred embodiment of the
invention can be installed, i.e., placed and fastened in their
proper position in the building as constructed, in approximately 1
hour by 6 workers without the need for any measuring or cutting of
any materials, and without the need for any crane or other lifting
device. The building components of the preferred embodiment of the
invention also include a plurality of preassembled, modular roof
trusses 60. Each roof truss 60 is triangular shaped in the
preferred embodiment, having 2 ends 61 and an apex 63, as shown in
FIGS. 11 and 12.
[0076] In the preferred embodiment of the invention, as depicted in
FIG. 12, each roof truss 60 measures approximately 16.5 feet long,
more preferably 16'9.26'', from one end to the other, and is
approximately 2.25 feet high, more preferably 28.71'', and fits
comfortably loaded inside a 20-foot ISO container 12, nested on top
of the ceiling panels 40 as shown in FIGS. 3 and 4.
[0077] Each roof truss 60 is preferably preassembled, prior to
being loaded and shipped in container 12, and is comprised a
plurality of roof truss framing members 64. Roof truss framing
members 64 are preferably comprised of metal studs having a
channel-shaped profile, said studs preferably having the following
dimensions: metal thickness of 0.75 mm; stud width of 1.61inches
(41 mm);
[0078] and stud depth of 3.50 inches (89 mm)
[0079] Each preassembled roof truss 60 preferably has a total
weight of approximately 42 pounds, sufficiently light to be carried
by 2 workers without the need for using a crane or other lifting
device, as such devices are generally unavailable in remote
locations where the present invention may be deployed.
[0080] In the preferred embodiment of the invention, the loaded
container 12 includes a total of 9 roof trusses 60. Roof trusses 60
may be unloaded from container 12 at the desired building site by
soldiers or other workers who carry the roof trusses 60 from
container 12 to the building site. After the building walls and
ceiling panels have been erected, the roof trusses 60 are then
lifted in place by the workers, such that the trusses rest upon and
are supported by the ceiling panels 40, as shown in FIGS. 10 and
11.
[0081] When used in erecting the preferred building of the present
invention, the roof trusses 60 are spaced 4 feet apart from each
other so as to span the 32 foot distance between the front wall 32
and the rear wall 34 of building 10.
[0082] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration. Accordingly, if building 10 for example
has a width of 20 feet rather than 16 feet, the roof trusses 60
will have a corresponding length of 20 feet, sufficient to span the
distance between side walls 36 and 38 of the building.
[0083] Similarly, it is understood that the building of the present
invention is not limited to the preferred roof pitch shown in FIG.
17, which is approximately 1-rise-to-3.5-run, more preferably
14.degree.. The desired roof pitch may be attained by providing
each roof truss 60 with an apex 63 extending a desired distance
above roof truss horizontal framing member 64h.
[0084] Roof trusses 60 are preferably fastened to supporting
ceiling and wall panels by use of suitable fastening means such as
screws, which are among the building components loaded and
transported in container 12 of the present invention.
[0085] The 9 roof trusses 60 in the preferred embodiment of the
invention can be installed, i.e., placed and fastened in their
proper position in the building as constructed, in approximately 1
hour by 4 workers without the need for any measuring or cutting of
any materials, and without the need for any crane or other lifting
device.
[0086] The building components of the preferred embodiment of the
invention also include a plurality of preassembled, modular roof
panels 70, as depicted in FIGS. 13, 14 and 15. In the preferred
embodiment of the invention, each roof panel 70 is approximately 8
feet wide and 91/2 feet long, more preferably 8'1.16'' by 9'7.23'',
and fits comfortably inside a 20-foot ISO container 12 as shown in
FIGS. 3 and 4.
[0087] Each roof panel 70 is preferably preassembled prior to being
loaded and shipped in container 12, and is comprised of a plurality
of roof panel framing members 74. Roof panel framing members 74 are
preferably comprised of metal studs having a channel-shaped
profile, said studs preferably having the following dimensions:
metal thickness of 0.75 mm; stud width of 1.61 inches (41 mm); and
stud depth of 3.50 inches (89 mm)
[0088] Each preassembled roof panel 70 preferably has a total
weight of approximately 68 pounds, sufficiently light to be carried
by 2 workers without the need for using a crane or other lifting
device, as such devices are generally unavailable in remote
locations where the present invention may be deployed.
[0089] In the preferred embodiment of the invention, the loaded
container 12 includes a total of 8 roof panels 70. Roof panels 70
may be unloaded from container 12 at the desired building site by
soldiers or other workers who carry roof panels 70 from container
12 to the building site. After the wall panels 20, ceiling panels
40 and roof trusses 60 have been erected, the roof panels 70 are
then lifted in place by the workers, such that the roof panels 70
rest upon and are supported by roof trusses 60. When used in
erecting the preferred building of the present invention, each roof
panel 70 rests upon and is supported by 3 roof trusses 60, as shown
in FIGS. 13 and 15.
[0090] In the preferred embodiment of the invention, wherein
building 10 has a rectangular footprint measuring 16 feet wide by
32 feet long, with a roof pitch of 14.degree. as shown in FIG. 17,
each roofing panel 70 is 8 feet and 1.16 inches wide, and 9 feet
and 7.23 inches long.
[0091] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration having the roof pitch shown in FIG. 17.
Accordingly, if building 10 for example has a width other than 16
feet and/or a roof pitch other than as shown in FIG. 17, each of
the roof panels 70 will have a corresponding length sufficient to
extend from at least the apex 63 to an end 61 of a supporting roof
truss 60.
[0092] Each roof panel 70 is preferably fastened to supporting roof
trusses 60 by use of suitable fastening means such as screws, which
are among the building components loaded and transported in
container 12 of the present invention.
[0093] The 8 roof panels 70 in the preferred embodiment of the
invention can be installed, i.e., placed and fastened in their
proper position in the building as constructed, in approximately
0.50 hours by 4 workers without the need for any measuring or
cutting of any materials, and without the need for any crane or
other lifting device.
[0094] In the preferred embodiment of the invention, the preferred
preassembly of metal studs used as framing member 24, 44, 64 and 74
and 114 includes the use of a profile-forming machine from the
Frame Master Company of Auckland, New Zealand. A roll of flat metal
stock material, preferably high tensile steel, is passed through
the machine, said flat metal stock having a preferred width of 181
mm and a preferred thickness of 0.75 mm. The machine has a series
of rollers and punches that form the flat metal stock passing
therethrough into a framing member having a "c" or channel profile
that is preferably 89 mm wide and 41 mm deep, with a 5 mm wide lip
formed on the inside to each side of the channel. The machine also
punches out holes in the framing members being formed, said holes
accommodating screw connectors which can be passed therethrough to
facilitate attachment of the framing members to each other and to
other components of the building as it is being erected.
[0095] The machine is also used to punch holes, preferably 25 mm in
size, out of the central 89 mm section of the stud, in appropriate
locations to accommodate the passage therethrough of electrical
wires, telecommunication cables and the like, as for example
openings 23 as shown in FIG. 5. The 5 mm lips to the inside of the
c-shaped channel are notched to permit the insertion and joining of
channel sections.
[0096] The building components of the preferred embodiment of the
invention further include roof cladding 80 and wall cladding 90
which are used, respectively, to face the roof and walls of
building 10. In the preferred embodiment of the invention, the roof
cladding 80 and wall cladding 90 are shipped in container 12 as
pre-cut sheets, which can be off-loaded at the desired building
site and rapidly attached to the building. As shown in FIGS. 3 and
4, the roof and wall cladding 80 and 90 is preferably shipped
nested in sheets between roof panels 70 and ceiling panels 40.
[0097] In the preferred embodiment of the invention, the sheets of
roof and wall cladding (sometimes referred to in the industry as
"standing seam material") are preassembled from flat galvanized
metal stock prior to being loaded into container 12. The preferred
preassembly of the roof and wall cladding includes the use of a
profile-forming machine from New Tech Machinery Corp. of Denver,
Colo. A roll of flat metal stock material is passed through the
machine, which forms a "profile" running the length of the stock
material, as for example the v-shaped profile 140 depicted in FIG.
20. The profile gives the material desired rigidity against
bending, and the material is cut into desired sheet lengths. In
addition, the profile-forming machine forms interlocking seams
along both edges of the stock material, running along its length.
Said interlocking seams provide a means for clipping or fastening
together adjoining sheets of cladding.
[0098] As shown in FIG. 15, sheets of roof cladding 82 are placed
on top of roof panels 70. In the preferred embodiment of the
invention, where building 10 has a footprint measuring 16 feet wide
and 32 feet long, with a roof pitch of approximately
1-rise-to-3.5-run, more preferably 14.degree., each sheet 82 of
roof cladding 80 is preferably 500 mm wide and is 9'8'' feet long,
and the loaded container 12 includes a total of 40 sheets 82 of
roof cladding 80.
[0099] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration having the roof pitch shown in FIG. 17.
Accordingly, if building 10 for example has a width other than 16
feet and/or a roof pitch other than as shown in FIG. 17, each sheet
82 of roof cladding 80 will have a corresponding length sufficient
to extend from at least the roof apex to an end of a supporting
roof panel 70.
[0100] Adjacent sheets 82 of roof cladding 80 are preferably
fastened together along their adjoining edges by the use of
suitable fastening means such as interlocking seams running
longitudinally along the edges of the sheets 82. The roof cladding
is fastened to the roof panels 70 of building 10 by suitable
fastening means such as screws. The fastening means for roof
cladding 80 are among the building components loaded and
transported in container 12 of the present invention.
[0101] Each pre-cut sheet 82 of roof cladding 80 in the preferred
embodiment of the invention is manufactured from flat metal stock
which is approximately 0.50 mm thick. Each sheet 82 has a weight of
approximately 15 pounds, sufficiently light to be carried by 1
worker and placed on top its supporting roof panel 70 without the
need for any crane or other lifting device.
[0102] In the preferred embodiment of the invention, the forty
pre-cut sheets 82 of roof cladding 80 can be installed, i.e.,
placed and fastened in their proper position in the building as
constructed, in approximately 1 hour by 2 workers without the need
for any measuring or cutting of any materials, and without the need
for any crane or other lifting device.
[0103] As shown in FIG. 16, wall cladding 90 is placed over the
wall panels 20. Wall cladding 90 includes sheets of side wall
cladding 92 and sheets of front and rear wall cladding 94. In the
preferred embodiment of the invention, where building 10 is 32 feet
long, with a side wall height of 8 feet, each sheet of side wall
cladding 92 is approximately 500 mm wide and is 8 feet long, and
the loaded container 12 includes a total of at least forty sheets
of side wall cladding 92. The last sheets of side wall cladding 92,
where the side walls meet the rear wall, are each precut
longitudinally so as to provide a cladding sheet width of
approximately 4 inches to fit the remaining portions of side wall
to be covered in the preferred building of the invention. Some
sheets of side wall cladding 92 are also precut as needed to
accommodate wall openings for building accessories such as air
conditioners 141, as shown in FIG. 1.
[0104] It is understood that building 10 of the present invention
is not necessarily limited to a building length of 32 feet, or a
side wall height of 8 feet. Accordingly, if building 10 for example
has a length other than 32 feet and/or a side wall height other
than as shown in FIG. 17, each sheet of side wall cladding 92 will
have a corresponding length sufficient to cover the entire side
wall, from top to bottom, with a sufficient number of side wall
sheets to completely cover the side walls from the front to the
rear of the building.
[0105] In the preferred embodiment of the invention, where building
10 is 16 feet wide with the roof pitch shown in FIG. 17, each sheet
of front and rear wall cladding 94 will be in the shape of a
trapezoid, as best shown in FIG. 16. Each sheet 94 is approximately
500 mm wide, with varying lengths sufficient to cover the front and
rear walls from top to bottom, as shown in FIG. 16. The last sheets
of front and rear wall cladding 94, where the front and rear walls
meet the side walls, are precut longitudinally so as to provide a
cladding sheet width of approximately 16 inches to fit the
remaining portions of the front and back walls to be covered in the
preferred building of the invention. Some sheets of front and rear
wall cladding 94 are also precut as needed to accommodate wall
openings for building accessories such as a door 143 and vent 145,
as shown in FIG. 2.
[0106] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration having the roof pitch shown in FIG. 17.
Accordingly, if building 10 for example has a width other than 16
feet and/or a roof pitch other than as shown in FIG. 17, each sheet
of front and rear wall cladding 94 will have a corresponding length
sufficient to cover the front and rear walls from top to bottom,
with enough such sheets 94 loaded into container 12 to completely
cover the front and rear walls of the building. Adjacent sheets of
wall cladding 90 are preferably fastened together along their
adjoining edges by the use of suitable fastening means such as
interlocking seams running longitudinally along the edges of sheets
92 and 94. The wall cladding is fastened to wall panels 20 of
building 10 by suitable fastening means such as screws. The
fastening means for the wall cladding 90 are among the building
components loaded and transported in container 12 of the present
invention.
[0107] Each pre-cut sheet of wall cladding 90 in the preferred
embodiment of the invention is manufactured from flat metal stock
which is approximately 0.5 mm thick. Each sheet of wall cladding 90
has a weight ranging from 15 to 20 pounds, sufficiently light to be
carried by workers and placed over the wall panels 20 without the
need for any crane or other lifting device.
[0108] All the wall cladding can be installed, i.e., placed and
fastened in their proper position in the building as constructed,
in approximately 2 hours by 4 workers, without the need for any
measuring or cutting of any materials, and without the need for any
crane or other lifting device.
[0109] Four pieces of corner flashing 147, shown in FIG. 20, are
shipped in and with the container 12, each piece of corner flashing
being long enough, approximately 8 feet in the preferred
embodiment, to cover each of the building corners. The corner
flashing pieces may be attached to the building via any suitable
means, such as metal screws.
[0110] In the embodiment of the present invention wherein
preassembled modular floor panels are shipped in and with container
12, each such floor panel 110 preferably includes 2 full sheets 112
of fiber cement wall board, as shown in FIG. 21. Each sheet 112 is
preferably 4 feet wide, 8 feet long and 0.750 inches thick. As
shown in FIG. 21, each floor panel 110 may be preassembled, prior
to being loaded and shipped in container 12, by affixing 2 adjacent
sheets 112 to floor framing members 114, such that each
preassembled floor panel 110 is approximately 16 feet long by 4
feet wide. Floor framing members 114 are preferably comprised of
metal studs having a channel-shaped profile, said studs preferably
having the following dimensions: metal thickness of 0.75 mm; stud
width of 1.61 inches (41 mm); and stud depth of 3.50 inches (89 mm)
Sheets 112 are preferably attached to framing members 114 by
fastening means such as screws, which are inserted through sheet
112 and into a supporting framing member 114 below.
[0111] In the alternative, the floor panels 110 may be loaded and
shipped in container 12 without first attaching sheets 112 to floor
framing members 114. This alternative may be especially desirable
due to weight lifting considerations, as each sheet 112 weighs
approximately 154 pounds. In said alternative, when the container
arrives at the desired building site and is unloaded, the
preassembled floor framing members 114 may be carried to and placed
into a desired position at the building site, and then sheets 112
may be fastened to them as described above.
[0112] As preassembled, each floor panel 110 has a finished inner
surface 116 and an outer surface 118. The finished inner surface
116 may be covered with vinyl, linoleum or some other suitable
flooring material glued or otherwise attached to the fiber cement
wall board. The outer surface 118 of preassembled floor panel 110
is preferably covered with floor insulation 120.
[0113] Each preassembled floor panel 110, with two adjacent sheets
112 fixed in place, has a total weight of approximately 373 pounds,
sufficiently light to be carried by 6 workers without the need for
using a crane or other lifting device, as such devices are
generally unavailable in remote locations where the present
invention may be deployed. If an embodiment is desired with lighter
carrying components for floor panels 110, then the floor panel may
be shipped and erected in accordance with the alternative described
above, where each sheet 112 weighs approximately 154 pounds and can
be carried by 4 workers, and the preassembled floor framing members
of each floor panel 110 have a total weight of approximately 65
pounds and can be carried by 2 workers.
[0114] In the embodiment of the present invention wherein
preassembled floor panels 110 are shipped in and with container 12,
the loaded container 12 includes a total of 8 floor panels 110,
each floor panel 110 measuring 4 feet wide by 16 feet long, which
are used to form the floor of building 10 having a rectangular
footprint measuring 16 feet wide and 32 feet long.
[0115] It is understood that building 10 of the present invention
is not necessarily limited to a 16 foot wide by 32 foot long
rectangular configuration. Accordingly, if building 10 for example
has a width of 20 feet rather than 16 feet wide, the floor panels
110 will each have a corresponding length of 20 feet, sufficient to
span the distance between the side walls 36 and 38 of the
building.
[0116] The floor panels 110 or their component parts may be
unloaded from container 12 at the building site by soldiers or
other workers as described in the alternatives above, who carry
them from container 12 to the building site. The floor panels 110
are erected at the desired building site by placing them into
position on the ground, preferably on supporting ground beams which
have already been positioned there, with the finished inner surface
116 of each floor panel 110 facing upward.
[0117] Ground beams may be 16 feet long, extending the length of
the floor panel, with adjacent ground beams spaced 18 inches apart,
from centerline to centerline. The ground beams sit directly on the
ground at the desired building site, which has preferably been
prepared by clearing away ground debris and otherwise leveling the
ground.
[0118] The ground beams may be joined together by short,
intermediate braces which preferably run perpendicular to the
ground beams and prevent individual ground beams from overturning
or otherwise moving with respect to each other. Each ground beam
preferably has a cross section which is 89 mm wide and 250 mm
high.
[0119] Ground beams may be assembled by fastening together a
multitude of metal studs having the same channel-shaped profile,
metal thickness, stud width and stud depth as floor framing members
114, with each stud preferably 250 mm long. Such studs, when stood
on end and fastened together, can be used to form a ground beam
which is 250 mm high and 89 mm wide, with a sufficient number of
studs fastened together to form a ground beam 16 feet long. The
open ends of the studs, top and bottom, may be faced with c-shaped
metal covers, each preferably 16 feet long and 89 mm wide. Such
ground beams may be shipped in and with the container.
[0120] Suitable ground anchors, preferably the 3/4 inch by 30 inch
"Iron Root" anchor with stabilizing disc available from Tie Down
Engineering of Atlanta, Georgia, may be shipped in and with the
container 12, said anchors being used to secure the floor panels
and ground beams to the supporting ground below. In the preferred
embodiment of the invention, wherein building 10 has a rectangular
footprint measuring 16 feet wide and 32 feet long, 8 floor panels
110 placed side-by-side span the 32 foot distance between the front
and rear walls 32 and 34 of the building, establishing the
footprint of the building.
[0121] Adjacent floor panels 110 are preferably fastened together
along their adjoining edges by the use of suitable fastening means
such as screws. Side walls 36 and 38 and front and rear walls 32
and 34 are set in place on the 32 ft..times.16 ft. perimeter edge
of the supporting floor panels 110. The walls are preferably
fastened to the floor panels by fastening means such as screws,
which are among the building components loaded and transported in
container 12 of the present invention.
[0122] In the preferred embodiment of the invention, the 8 floor
panels 110 can be installed, i.e., fastened together and anchored
to the ground at the desired building site, in approximately 0.50
hours by 6 workers without the need for any measuring or cutting of
any materials, and without the need for any crane or other lifting
device.
[0123] In the preferred embodiment of the invention, the building
includes, on all four exterior and interior corners, upper and
lower sets of metal "L" brackets 130. As shown in FIG. 20, each set
130 of "L" brackets includes an outside bracket 132 and a
corresponding inside bracket 134. Each "L" bracket is preferably
made of metal which is approximately 5 mm thick and 2.5 inches
high, with each leg of the bracket extending horizontally about 8
inches. Outside bracket 132 and inside bracket 134 of each set 130
are fastened together, preferably through the use of carriage bolts
135. Carriage bolts 135 pass completely through the building wall,
from wall cladding 90 to the finished inner surface 26 of wall
panel 20, as shown in FIG. 20. An interior corner trim piece 136
may also be provided at each interior corner of the building. In
the preferred embodiment of the invention, eight sets of "L"
brackets, 16 carriage bolts, and 4 interior corner trim pieces are
loaded and shipped in container 12.
[0124] The preferred embodiment of the present invention also
includes additional building components, supplies and tools which
are loaded in the container and transported to the desired building
site, including the following: window air conditioners 141;
building door 143; attic vent 145; lighting fixtures 149; roof
ridge cap 151; soffit 153; and facia 155; box 157 of fabricating
tools including screwdrivers and screws; boxes 159 containing
electrical items including electric outlets, switches, wiring, wire
nuts and electric tape; and rolls 161 of fiberglass insulation, all
of which may be used for and with building 10 in accordance with
well-established construction practice.
[0125] When the building of the present invention has been
constructed at the desired building site, a local source of
electric power may be used to power the building.
TABLE-US-00001 PARTS LIST PART NO. DESCRIPTION 10 Finished building
of the present invention 12 Shipping container 14 Doors of shipping
container 12 20 Preassembled, modular wall panel 22 Sheet of wall
board of wall panel 23 Opening in framing member 24 24 Wall framing
member 25 Opening in wall panel 20 to accommodate an electrical
outlet 26 Finished inner surface of wall panel 20 27 Opening in
wall panel 20 to accommodate an air conditioner 28 Outer surface of
wall panel 20 29 Opening in wall panel 20 to accommodate a door 30
Wall insulation 32 Front wall of building 34 Rear wall of building
36 Left side wall of building 38 Right side wall of building 40
Preassembled, modular ceiling panel 42 Sheet of wall board of
ceiling panel 40 44 Ceiling framing member 46 Finished inner
surface of ceiling panel 40 48 Outer surface of ceiling panel 40 50
Ceiling insulation 60 Preassembled, modular roof truss 61 End of
roof truss 63 Apex of roof truss 64 Roof truss framing member 64h
Roof truss horizontal framing member 70 Preassembled, modular roof
panel 74 Roof panel framing member 80 Roof cladding 82 Sheet of
roof cladding 90 Wall cladding 92 Sheet of side wall cladding 94
Sheet of front and rear wall cladding 100 Omega clip 110
Preassembled modular floor panel 112 Sheet of wall board of floor
panel 110 114 Floor framing member 116 Finished inner surface of
floor panel 110 118 Outer surface of floor panel 110 120 Floor
insulation 130 "L" bracket set 132 Outside "L" bracket 134 Inside
"L" bracket 135 Carriage bolt 136 Interior corner trim 140 Profile
in cladding 141 Air conditioner 143 Door 145 Vent 147 Corner
flashing 149 Lighting fixture 151 Roof ridge cap 153 Soffit 155
Facia 157 Box of fabricating tools 159 Box of electrical items 161
Roll of insulation
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