U.S. patent application number 14/006578 was filed with the patent office on 2014-01-02 for building construction.
This patent application is currently assigned to TEKTUM LTD. The applicant listed for this patent is Thomas Addison Grant, Nicolas Jean Paul Perren. Invention is credited to Thomas Addison Grant, Nicolas Jean Paul Perren.
Application Number | 20140000183 14/006578 |
Document ID | / |
Family ID | 46878549 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140000183 |
Kind Code |
A1 |
Perren; Nicolas Jean Paul ;
et al. |
January 2, 2014 |
Building Construction
Abstract
In one preferred from there is provided a building construction
136. The building construction comprises a body portion 140 having
a floor extension 142 adapted to extend from the body portion 142
and provide a floor area 144 wherein the floor extension 142
includes a facility 146 for receiving a building module.
Inventors: |
Perren; Nicolas Jean Paul;
(Rushcutters Bay, AU) ; Grant; Thomas Addison;
(Rushcutters Bay, AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Perren; Nicolas Jean Paul
Grant; Thomas Addison |
Rushcutters Bay
Rushcutters Bay |
|
AU
AU |
|
|
Assignee: |
TEKTUM LTD
Rushcutters Bay, NSW
AU
|
Family ID: |
46878549 |
Appl. No.: |
14/006578 |
Filed: |
March 22, 2012 |
PCT Filed: |
March 22, 2012 |
PCT NO: |
PCT/AU2012/000309 |
371 Date: |
September 20, 2013 |
Current U.S.
Class: |
52/79.5 ;
52/745.02 |
Current CPC
Class: |
Y02A 50/00 20180101;
E04B 1/34869 20130101; E04B 1/348 20130101; Y02A 50/14 20180101;
E04H 9/145 20130101; E04H 2001/1283 20130101; E04H 1/005 20130101;
E04B 1/3444 20130101 |
Class at
Publication: |
52/79.5 ;
52/745.02 |
International
Class: |
E04B 1/348 20060101
E04B001/348 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 22, 2011 |
AU |
2011901059 |
Claims
1-133. (canceled)
134. A building having internal flooring and a central roof section
between two butterfly roof sections, wherein: the building is
partly formed from a container having a floor, removable side walls
and a roof; the internal flooring is formed by horizontally
abutting the removable side walls of the container against opposite
side edges of the floor of the container; the two butterfly roof
sections are formed by roof modules hinged in series along opposite
side edges of the roof of the container; and the central roof
section is formed by the roof of the container; wherein at least
one of the removable side walls of the container has a removable
portion that forms external flooring of the building; and wherein
an amenities module is insertable into a cutout left in the at
least one removable side wall after removal of the removable
portion therefrom.
135. A building according to claim 134, further including regularly
spaced apart columns that support the butterfly roof sections above
the internal flooring.
136. A building according to claim 135, further including
interchangeable wall modules removably attached to the columns to
form reconfigurable walls of the building.
137. A building according to claim 134, wherein the container has
ISO standard external dimensions.
138. A method of forming a building having internal flooring and a
central roof section between two butterfly roof sections, the
method including: providing a container having a floor, removable
side walls and a roof; forming the internal flooring by
horizontally abutting the removable side walls of the container
against the floor of the container; forming the two butterfly roof
sections by hinging roof modules in series along opposite side
edges of the roof of the container; wherein the central roof
section is formed by the roof of the container; wherein at least
one of the removable side walls of the container has a removable
portion that forms external flooring of the building; and wherein
an amenities module is insertable into a cutout left in the at
least one removable side wall after removal of the removable
portion therefrom.
139. A method according to claim 138, further including providing
regularly spaced apart columns that support the butterfly roof
sections above the internal flooring.
140. A method according to claim 138, further including removably
attaching interchangeable wall modules to the columns to form
reconfigurable walls of the building.
141. A method according to claim 138, wherein the container has ISO
standard external dimensions.
142. A kit of parts for forming a building having internal flooring
and a central roof section between two butterfly roof sections, the
kit of parts including: a container having a floor, removable side
walls and a roof, wherein the internal flooring is formed by
horizontally abutting the removable side walls of the container
against opposite side edges of the floor of the container; and roof
modules that are hingeable in series along opposite side edges of
the roof of the container to form the two butterfly roof sections;
wherein the central roof section is formed by the roof of the
container; wherein at least one of the removable side walls of the
container has a removable portion that forms external flooring of
the building; and wherein an amenities module is insertable into a
cutout left in the at least one removable side wall after removal
of the removable portion therefrom.
143. A kit of parts according to claim 142, further including
columns to support the butterfly roof above the internal
flooring.
144. A kit of parts according to claim 143, further including
interchangeable wall modules that are removably attachable to the
columns to form reconfigurable walls of the building.
145. A kit of parts according to claim 142, wherein the container
has ISO standard external dimensions.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a building construction. In
one form of the present invention there is provided a prefabricated
building unit for transport as an ISO standard shipping
container.
BACKGROUND TO THE INVENTION
[0002] There is a need for affordable and sustainable mass produced
buildings, and dwellings. The current techniques of building
houses, for example, are typically very manual and expensive. Most
of a typical house is constructed on site. Skilled labour is
required to build the house and connect the required services.
Furthermore, it takes a considerable amount of time, typically many
months, to build a house.
[0003] It is against this background and the problems and
difficulties associated therewith that the present invention has
been developed.
SUMMARY OF THE INVENTION
[0004] According to the present invention, there is provided a
building having internal flooring and a central roof section
between two butterfly roof sections, wherein: [0005] the building
is partly formed from a container having a floor, removable side
walls and a roof; [0006] the internal flooring is foamed by
horizontally abutting the removable side walls of the container
against opposite side edges of the floor of the container; [0007]
the two butterfly roof sections are formed by roof modules hinged
in series along opposite side edges of the roof of the container;
and [0008] the central roof section is formed by the roof of the
container; [0009] wherein at least one of the removable side walls
of the container has a removable portion that forms external
flooring of the building; and [0010] wherein an amenities module is
insertable into a cutout left in the at least one removable side
wall after removal of the removable portion therefrom.
[0011] The present invention also provides a method of forming a
building having internal flooring and a central roof section
between two butterfly roof sections, the method including: [0012]
providing a container having a floor, removable side walls and a
roof; [0013] forming the internal flooring by horizontally abutting
the removable side walls of the container against the floor of the
container; [0014] forming the two butterfly roof sections by
hinging roof modules in series along opposite side edges of the
roof of the container; [0015] wherein the central roof section is
formed by the roof of the container; [0016] wherein at least one of
the removable side walls of the container has a removable portion
that forms external flooring of the building; and [0017] wherein an
amenities module is insertable into a cutout left in the at least
one removable side wall after removal of the removable portion
therefrom.
[0018] The present invention further provides a kit of parts for
forming a building having internal flooring and a central roof
section between two butterfly roof sections, the kit of parts
including: [0019] a container having a floor, removable side walls
and a roof, wherein the internal flooring is formed by horizontally
abutting the removable side walls of the container against opposite
side edges of the floor of the container; and [0020] roof modules
that are hingeable in series along opposite side edges of the roof
of the container to form the two butterfly roof sections; [0021]
wherein the central roof section is formed by the roof of the
container; [0022] wherein at least one of the removable side walls
of the container has a removable portion that forms external
flooring of the building; and [0023] wherein an amenities module is
insertable into a cutout left in the at least one removable side
wall after removal of the removable portion therefrom.
[0024] According to a first aspect of preferred embodiments herein
described there is provided a building construction comprising a
body portion having a floor extension adapted to extend from the
body portion and provide a floor area wherein the floor extension
includes a fitting facility for receiving a building module.
[0025] According to a second aspect of preferred embodiments herein
described there is provided a building construction having a body
portion of a box configuration suitable for transportation as a
transport container wherein the body portion has an upper structure
having at least two elongate upper external edge portions with a
gutter arrangement disposed inwardly of and along at least one of
the two elongate upper edge portions.
[0026] According to a third aspect of preferred embodiments herein
described there is provided a building construction comprising: a
body portion and a gutter arrangement wherein the gutter
arrangement includes a moveable hinge portion and a gutter portion,
the moveable hinge portion being adapted to mount a roof extension
to the body portion, the moveable hinge portion being movable to
allow the roof extension to be inclined at angle relative to the
body portion in a position adjacent the gutter portion such that
when water falls onto the roof extension the water will flow
downwardly along the roof extension into the gutter portion.
[0027] According to a fourth aspect of preferred embodiments herein
described there is provided a building construction comprising: a
body portion having an upper structure and a lower structure, the
lower structure being adapted to provide at least one water
compartment, the at least one water compartment being adapted to be
emptied and provide the lower structure with sufficient buoyancy to
lift the body portion in flood conditions.
[0028] According to a fifth aspect of preferred embodiments herein
described there is provided a building construction comprising: at
least one module, the or each module being adapted to be provided
as ISO shipping container, when in a transport condition; the at
least one module being adapted to provide a building body which has
a floor area at least 2.5 times the combined horizontal area of the
modules, when in the transport condition; and a panel system
comprising a plurality of interchangeable panels allowing the
building to be provided with different facade layouts suited to
different site orientations and other conditions.
[0029] According to a sixth aspect of preferred embodiments herein
described there is provided a building construction comprising: a
body portion; and panel system; wherein the panel system comprises
a number of interchangeable panels that can be arranged to provide
the body portion with different facade layouts so as to adapt
building to different site orientations and conditions.
[0030] According to a seventh aspect of preferred embodiments
herein described there is provided a building construction for
providing a building, the building construction comprising a body
portion, a floor extension and a moveable hinge portion, the hinge
portion mounting the floor extension to the lower end of the body
portion such that the floor extension is moveable between collapsed
and extended conditions; wherein in the collapsed condition the
floor extension provides side walls of the building construction at
least in part providing the building construction with ISO shipping
certification; further wherein the building construction comprises
a roof extension that is put onto the building after the floor
extension has been moved to the extended condition, the floor
extension being of a heavy weight in comparison to the roof
extension.
[0031] According to an eighth aspect of preferred embodiments
herein described there is provided a method of construction
comprising: providing a building construction; swinging out floor
extensions provided as side walls that at least in part provide the
building constructions as an ISO shipping container wherein the
floor extensions are of a substantial weight; and then attaching
roof extensions to the building construction where the roof
extension are of a relatively light weight.
[0032] According to a ninth aspect of preferred embodiments herein
described there is provided a method of construction comprising:
providing a building construction, positioning roof and flooring
extensions relative to a body of the building construction; and
providing a flotation arrangement beneath the floor extensions to
assist with lifting the building construction during flood
conditions.
[0033] According to a tenth aspect of preferred embodiments herein
described there is provided a method of construction comprising:
providing a building construction; extending floor extensions to
provide an extended floor area; using a facility of the floor
extensions to receive a building module; positioning the building
module such that the building module provides a portion of the
floor area of the building construction.
[0034] According to an eleventh aspect of preferred embodiments
herein described there is provided a method of construction
comprising: providing a building construction; positioning roof and
flooring extensions relative to a body of the building
construction; using a hinge of a gutter arrangement to dispose the
roof extension in an inclined condition relative to the body of the
building construction such that when water falls onto the roof
extension the water flows flow downwardly along the roof extension
into the a gutter portion of the gutter arrangement.
[0035] According to a twelfth aspect of preferred embodiments
herein described there is provided a unit for a building, the unit
comprising: a base; and a roof supported above the base.
[0036] According to a thirteenth aspect of preferred embodiments
herein described there is provided a building construction
providing a transportable module, the transportable module
providing kitchen or bathroom facilities for installation within a
larger building construction.
[0037] As will be discussed there are considered to be a number of
preferred arrangements of the present invention that
advantageously: [0038] (i) Provide room areas having an improved
feeling of spaciousness and comfort in a building constructed using
prefabricated ISO standard container modules, where the building is
still relatively readily manufactured and installed. [0039] (ii)
Provide buildings, constructed using prefabricated ISO standard
container modules, having advantageous rain capture and
waterproofing capabilities while still being relatively readily
manufactured and installed. [0040] (iii) Provide ISO standard
container modules having prefabricated fold out floor extensions,
where during construction, the containers are placed side by side
to provide a building of advantageous size and the building is able
to receive a building module. [0041] (iv) Provide systems having
one or more containers each with a floor portion where the floor
portion can be folded to triple the floor space. [0042] (v) Provide
a building constructed using prefabricated ISO standard container
modules with advantageous flood protection capabilities. [0043]
(vi) Provide systems formed from at least one ISO shipping
container module having a plurality of panels that allow the final
building to be provided with different facade layouts suited to
different site orientations and other conditions. [0044] (vii)
Provide systems and methods having an advantageous kitchen and
bathroom fitting facility and module.
[0045] Further aspects, advantages and preferred features will be
apparent from the drawings, claims and a reading of the
specification as a whole.
[0046] It is to be appreciated that each of the embodiments is
specifically described and that the present invention is not to be
construed as being limited to any specific feature or element of
any one of the embodiments. Neither is the present invention to be
construed as being limited to any feature of a number of the
embodiments or variations described in relation to the embodiments.
The term building construction is to be understood as embracing
transportable modules and building assemblies.
BRIEF DESCRIPTION OF DRAWINGS
[0047] In order to facilitate a better understanding of the present
invention, several preferred embodiments will now be described with
reference to the accompanying drawings, in which:
[0048] FIGS. 1 to 9 provide several views illustrating a method of
construction according to a first preferred embodiment of the
present invention;
[0049] FIG. 10 provides several views of a building construction
according to another preferred embodiment of the present
invention;
[0050] FIGS. 11 to 17 illustrate a completed building construction
according to a further embodiment, the building construction being
provided according to the method illustrated in FIGS. 1 to 9;
[0051] FIGS. 18 and 19 illustrate another building construction
according to a further preferred embodiment of the present
invention;
[0052] FIGS. 20a to 20f illustrate a further system and method
according to a further embodiment;
[0053] FIGS. 21 to 23 illustrate a kitchen bathroom module
according to yet another embodiment of the present invention;
[0054] FIG. 24 illustrates a building construction according to yet
another embodiment of the present invention;
[0055] FIGS. 25 to 27 illustrate a building construction according
to a further embodiment of the present invention; and
[0056] FIGS. 28 to 45 illustrate yet further preferred embodiments
of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0057] Referring to FIGS. 1 to 9 there is shown a method of
construction 10 according to a first preferred embodiment of the
present invention. Referring to FIG. 3, in particular, the method
of construction 10 employs two building constructions 12 that form
preferred embodiments of the present invention in their own right.
Advantageously the method 10 is considered to provide for the ready
construction of a building with several advantageous features that
are discussed below.
[0058] As shown in FIG. 1, the method of construction 10 provides a
footing arrangement 14. More particularly, in the footing
arrangement 14, the method 10 provides a plurality of first side
footings 16, a plurality of intermediate footings 18 and a
plurality of opposite side footings 20. A slide structure 22 in the
form of a pair of bearers 24 is also provided.
[0059] The first side footings 16 and the opposite side footings 20
form a plurality of rows 26 comprising a first row 28, a second row
30, a third row 32, and a fourth row 34. Advantageously the slide
structure 22 provides a first intermediate footing 36 and a second
intermediate footing 38 that form part of the first row 28.
[0060] Of the intermediate footings 18, an intermediate footing 40
forms part of the second row 30, an intermediate footing 42 forms
part of the third row 32 and an intermediate footing 44 forms part
of the fourth row 34.
[0061] As shown in FIG. 2, a first one of the building
constructions 12 is placed on: (i) the first side footings 16 of
the first row 28 and the second row 30; as well as on (ii) the
intermediate footing 36 and the intermediate footing 40. This is
performed using a crane.
[0062] The second building construction 12 is placed on: (i) the
opposite side footings 20 of the first row 28 and the second row
30; as well as on (ii) the intermediate footing 36 and the
intermediate footing 40. The intermediate footing 36 and
intermediate footing 40 are provided as "T" footings to
advantageously support both of the building constructions 12. In
the method 10 the building constructions 12 are secured to the
footings.
[0063] The two building constructions 12 are each provided as a
standard container module 46 certified to meet ISO shipping
standards. Each of the standard modules 46 comprises a body portion
48 having an advantageous gutter arrangement 50.
[0064] As shown in FIG. 4, the gutter arrangement 50 of each
standard module 46 includes a moveable hinge portion 52 and a
gutter portion 54. When in a collapsed condition for transport, as
shown in FIG. 3, each gutter arrangement 50 is advantageously
protected by a number of floor extensions 56 that are connected to
the lower portion 58 of each module 46. In the embodiment the floor
extensions 56 are connected to the lower portion 58 by a number of
butt hinges 60.
[0065] The floor extensions 56 are provided in the form of outer
panels and, in the method 10, are unfolded to form a floor area 62
as shown in FIG. 5. In order to provide the floor area 62, the top
of each of the floor extensions 56 is swung away from the upper
portion 64 of each respective module 46. The floor extensions 56
are brought to rest on and are secured to the footings 14.
[0066] FIGS. 6 to 8 illustrate the process of attaching a roof
extension 66 to the body portion 48 of each module 46. The moveable
hinge portions 52 of the modules 46 are adapted to mount a
plurality of roof components 68 in the form of roof panels to form
the roof extension 66 which is mounted to the body portions 48. The
moveable hinge portions 52 are able to move from a first position
70, shown in FIG. 4, to an intermediate position 72 shown in FIG.
6. In the method 10, a number of roof components 68 are attached in
series along the hinges 52 such that the roof components 68 extend
from one side of the overall structure to the other, to form the
roof extension 66.
[0067] Advantageously in the embodiment, the floor extensions 56
are of a relatively heavy weight in comparison to the roof
extension 66 so as to provide weight to base of the final building.
Advantageously, the floor extensions 56 provide a floor area that
feels similar to a house having a concrete floor in terms of the
stability provided. By folding down the floor extensions 56 first
the heaviest part is folded down. The roof extension 66 can then be
advantageously provided by lighter roof components that are
subsequently connected in the intermediate position 72 shown.
Assembly in this vertical-type position allows the person
assembling the building to advantageously assess the quality of the
water proofing of the completed roof extension 66. Six roof
components 68 are provided within each of the constructions 12
during transport to provide the overall roof extensions on either
side.
[0068] Returning to FIG. 7, the gutter arrangement 50 provides an
elongate channel 74 having a first lateral side portion 76 and a
second lateral side portion 78. The first lateral side portion 76
is configured for extending along the length of the body portion 48
and the second lateral side portion is configured for extending
along an along an edge portion 80 of the roof extension 66.
[0069] In the method 10, as shown in FIG. 8, the roof extension 66
is moved by an outward swinging movement with the hinges 52 moving
from the intermediate position 72 shown in FIG. 6 to an inclined
position 82 shown in FIG. 8. When the roof extension 66 has been
raised to a sufficient height a plurality of supporting members 84
are installed and secured in position using conventional attachment
means. The process is repeated on the opposite side of the each
module 46 which has an identical advantageous mirror image gutter
arrangement to provide a full extended building structure 86 shown
in FIG. 9. After this has been performed a number of supporting
brackets 88 are removed.
[0070] The form and arrangement of the building structure 86 is
considered to be advantageous given that the hinge portions 52 are
moveable from a vertical position shown in FIG. 3 to the
intermediate position 72 with the roof extension finally being
fixed in the inclined position 82 shown in FIG. 8.
[0071] The provision of the gutter arrangement 50 as described and
shown in the drawing is considered to serve to advantageously
protect the body portions 48 for water seepage and to provide
advantageous water capture in a prefabricated two module container
system.
[0072] Referring to FIG. 10 there is shown an advantageous building
construction 90 according to a further preferred embodiment. The
building construction 90 comprises a body portion 92 and a gutter
arrangement 94. The gutter arrangement 94 includes a moveable hinge
portion 96 and a gutter portion 98. The moveable hinge portion 96
is adapted to mount a roof extension 100 to the body portion 92.
The moveable hinge portion 96 is movable to allow the roof
extension 100 to be inclined at an upward angle relative to the
body portion 92 in a position adjacent the gutter portion 98. As
such when water falls onto the roof extension 100, the water is
caused by the action of gravity to flow downwardly along the roof
extension 100 into the gutter portion 98.
[0073] The gutter arrangement 94 is provided as an elongate channel
102 having a first lateral side portion 104 and a second lateral
side portion 106. The first lateral side portion 104 is configured
for extending along the length of the body portion 92 and the
second lateral side portion 106 is configured for extending along
an edge portion 108 of the roof extension 100.
[0074] In the embodiment the gutter arrangement 94 is provided on a
first side 110 of the building construction 90 and a `mirror image`
gutter arrangement 112 is provided on an opposite side 114. The
gutter arrangement 94 and the gutter arrangement 112 form an
overall gutter arrangement 116.
[0075] When in a condition for transport, both the gutter
arrangement 94 and the gutter arrangement 112 are advantageously
protected by lateral elongate side panels of the body portion 92 in
the form of two floor extensions 118. The two floor extensions 118,
in the transport condition, extend upwardly to protect the gutter
arrangement 94 and the gutter arrangement 112 from sideways damage
which could be caused by say a forklift.
[0076] As shown in FIG. 10, the gutter portion 98 is provided as a
u-shaped channel portion 120 located between the roof extension 100
and remainder of the body portion 92. By virtue of the channel
portion 120 being of a conventional size for a gutter, the channel
portion 120 is advantageously able to be readily cleaned using a
ladder and conventional extendable gutter cleaners.
[0077] In the gutter arrangement 94, the hinge portion 96 comprises
an elongate butt hinge 122 having a first leaf 124 for connection
to the gutter portion 98 and a second leaf 126 for connection to
the roof extension 100 as shown. Various hinge and connection
arrangements are of course possible.
[0078] The body portion 92 has a slightly inclined upper portion
128 for causing water falling on the included upper portion 128 to
flow into the gutter arrangement 94. In the embodiment the upper
portion 128 is inclined by being slightly convexly shaped.
[0079] As discussed each lateral side of the building construction
90 is provided by an elongate floor extension 118 adapted to extend
from the lower portion of the body portion 92 and provide a floor
area. The floor extensions 130 are latched in position for
transport purposes. The floor extensions extend slightly beyond the
central main portion 132 of the body portion 92 to provide strength
during transport. The width of each elongate floor extension 130
(vertical height) is only slightly greater than the height of the
main portion 132 of the body portion 92.
[0080] Advantageously, the hinge portion 96 of the gutter
arrangement 94 allows for the roof extension 100 to be
substantially wider than the height of the body portion 92 such
that when the building is assembled there is provided a desirable
feeling of spaciousness and comfort.
[0081] The embodiment is considered to provide a building
construction 90 having a body portion 92 of a box configuration
suitable for transportation as a transport container. The floor
extension 130 provides an upper structure having at least two
elongate upper external edge portions 134 provided by the floor
extensions 118 with the gutter arrangement 94 and the gutter
arrangement 112 being disposed inwardly thereof. The gutter
arrangements extend along the external edge portions 134 and
provide a channel 120 on the upper portion for the flow of water.
The building construction 90 is considered to be advantageous for
reasons discussed above.
[0082] Turning to FIG. 11, there is shown an overall building
construction 136 provided according to the method 10. The building
construction 136 comprises two modular building constructions 138
adapted to be transported as ISO certified shipping containers.
[0083] Each of the modular building constructions 138 includes a
body portion 140 having a floor extension 142 pivotally attached to
a lower portion of the respective body portion 140. In other
embodiments a pivotal attachment may not be provided, and the floor
extensions 142 may be positioned manually with say straps and
chains that are used to constrain the lower edge of each floor
extension 142 during lowering. Notably, with a manual positioning
system, without an integral pivot, it is also preferred that the
floor extensions are mounted vertically on the sides of the main
chassis of the building construction 138 during transport. This may
be advantageously achieved with a bolting system as is discussed in
further detail below with reference to FIGS. 18 and 19.
[0084] Returning to the embodiment of FIG. 11, each floor extension
142 is adapted to extend from the body portion 140 and provide a
floor area 144. As shown the floor area 144 provided by both
extensions 142, in combination, is about 2/3 of the total floor
area.
[0085] Moreover, each floor extension 142 includes a fitting
facility 146 for receiving a building module 148 in the form of a
kitchen or bathroom module 150 (See FIG. 13). The building
constructions 138 are provided as mirror images with the fitting
facility 146 being provided at a corner of each corresponding
building construction 138. By being provided as mirror images this
means that the fitting facilities 146 provide a central fitting
facility in the overall building construction 136.
[0086] Referring to FIGS. 11 to 13, each fitting facility 146
comprises a removable portion 152 that is removable from the
respective floor extension 142 to provide a floor recess 154 (See
FIG. 12) for receiving a corresponding half of the building module
148, (See FIG. 13).
[0087] As shown in the Figures, the recesses 154 are together
positioned on a lateral outer edge of the building construction
136, and are centrally positioned. Whilst each of the building
constructions 138 provides a recess that receives only half of the
horizontal cross-section of the building module 148, the recess 156
of the overall building construction 136 receives the full
cross-section of the building module (in the horizontal plane).
This is illustrated in FIG. 12. The recess 156 is provided by
removing centre panels that each form about half of the respective
floor extension 142.
[0088] Before the building module 148 is installed, a number of
water tanks 158 are provided in the centre of the building
construction 136. This is illustrated in FIG. 14.
[0089] As shown in FIG. 15, there is provided a sliding system 160
that is adapted to allow ready positioning of the building module
148. The sliding system 160 comprises two spaced apart bearers that
allow the building module 148 to be placed thereon and slid into
the recess 156 of the full building construction 136. As shown the
bearers extend perpendicularly from the building construction 136.
The bearers if relatively accurately positioned can also be used as
a guide. In the embodiment, the removable portions 152 are
advantageously used to provide further flooring in the form of a
verandah.
[0090] As shown in FIGS. 15 to 17, the building module 148 is
placed outside the house on the bearers. Module end caps are
removed and the module is slid along the bearers into the installed
position. Internal and exterior wall panels can then be
installed.
[0091] In the embodiment the building module comprises a
kitchen/bathroom module. Each floor extension is adapted to be
mounted vertically when in a transport condition and then to be
position horizontally to provide the floor area. The removable
portions are provided adjacent a top corner of the floor extensions
so that when removed a recess is relatively centrally provided to
accommodate the floor of a rectangularly configured recess/fitting
facility. Whilst the removable portions are preferred other
mounting arrangements allowing the incorporation of a
kitchen/bathroom module are of course possible. The overall recess
provided receives the full floor area of the building module.
[0092] Referring to FIG. 18 there is shown a further embodiment of
the present invention. The embodiment comprises a single 40 ft
building unit 139 that is advantageously provided as a unitary 40
ft ISO standard shipping container. A number of floor extensions
141 are bolted to a main chassis 143. The bolting occurs along top
edges 147 and bottom edges 149. Advantageously in the embodiment
the complete side of the building unit 139, including its top and
bottom corner fittings comprises a single welded frame of a floor
extension 141. This is illustrated in FIG. 18 and provides for
advantageous strength.
[0093] Additionally FIG. 19 illustrates the use of bolts 151 and
mounting portions 153 that are used to fix the floor extensions 141
to the main chassis 143 during transport. The mounting portions are
openly configured to allow ready access to the nuts that are used
to secure the opposite end of the bolts 151. Several configurations
are of course possible.
[0094] After unbolting, the floor extensions are moved from a
vertically mounted position and are then positioned horizontally to
form an extended floor area. This can be achieved by several
methods including say manually with straps, chains or brackets that
constrain the lower edge during assembly. The floor extensions 141
span the full height to the main chassis 143. This is considered to
be advantageous.
[0095] The building unit 139, in this embodiment, comprises a
single/unitary 40'ft reinforced container rather than two 20'
containers placed end to end. This is considered to significantly
reduce the number of components required and therefore cost, as
well as to simplify transportation and installation in several
cases. The fixing arrangement comprises the floor extensions 141
being bolted by extending the bolts 151 through the main peripheral
frame 155 of each floor extension 141. This is also considered to
be advantageous for the reason that the bolts are able to
advantageously transfer impact loads and maintain the floor
extensions 141 in a desirable position during transportation.
[0096] Referring to the Figures it is also shown that the floor
extensions 141 each advantageously form a complete side of the
container vertically and horizontally with respect to the chassis
143. The floor extensions 141 provide ISO standard corners 157 as
part of their outer frame 155. The ISO standard corner castings 157
are separate, as shown, from the centre chassis 143 to which the
floor extensions 141 are bolted. By bolting in this manner, the
floor extensions 141 are advantageously secured in a steadfast
manner.
[0097] The floor extensions 141 each provide a structural frame of
a similar structural reinforcement to the chassis 143 to which they
are bolted.
[0098] During installation the floor extensions 141 are detached
from the centre chassis 143 of the container, are lowered in to
position using a pivoting motion (but without an integral pivot)
and then are re-attached by bolting.
[0099] In addition, one of the floor extensions 141 of the unitary
40'ft building unit 139 advantageously provides a fitting facility.
The fitting facility is advantageously adapted to receive a
separate building construction in the form of a kitchen or bathroom
module. It is considered that allowing a separate building unit to
be inserted into the container, enables the advantageous provision
of relatively full sized rooms. In comparison to other container
building units the kitchen and bathroom is not positioned in the
relatively narrow central spine of the 40' container. In the
embodiment, a kitchen and bathroom module is received within/on one
of a floor extensions 141 extending from the base of the chassis
143.
[0100] Referring to FIGS. 20a to 20f there is shown a method of
construction 159 according to a further embodiment providing a
unitary 40 ft building unit. As shown the floor extensions provide
the ISO standard corners 161. The kitchen/bathroom module is
transported as a container having a floor 163. The kitchen/bathroom
unit also provides ISO end mounts 165 and a protecting roof 167.
During installation the floor 163 of the module, which is
transported separately, is then guided into position and forms part
of the final floor area. The protecting roof is reusable and
advantageously includes flooring as part of the protecting layering
for use as part of the verandah of the building.
[0101] FIGS. 21 to 23 illustrate a modular unit 169 according to a
further preferred embodiment of the present invention. The modular
unit 169 is advantageously provided as a 20 foot container 171. The
container 171 advantageously comprises a chassis 173 having a box
shaped frame 175 with an internal reinforcement 177. The frame 173
is elongate and includes a first end 179 and a second end 183.
[0102] A first carrier element 185 is mounted to the first end 179
and a second carrier element 187 (not shown) is mounted to the
second end 183. The carrier elements 185 and 187 are removably
attached to the chassis 172 and have a relatively flat planar
configuration. The removable attachment is provided a number of
bolting elements as shown. The carrier elements 185 and 187 are of
a shape protecting the periphery of the chassis 173 and
substantially span the full width and height of the ends 179,
183.
[0103] The carrier elements 185, 187 each include ISO corner
elements 189. The modular unit 169 is provided to ISO shopping
container standards. Furthermore, the modular unit 169 is designed
to provide both kitchen facilities and bathroom facilities for a
larger modular. unit of the type described above. By providing the
majority of the plumbing and kitchen facilities in the modular unit
169, other material such as roofing can be advantageously
transported in the larger modular unit (40 ft). The smaller modular
unit 169 containing the kitchen and bathroom facilities is
separately transported to the assembly site. The applicant
considers that this is advantageous.
[0104] The modular unit 169 may include low friction material on
its lower surface to assist with being moved on a plurality of
bearers mounted to the large modular unit during assembly. This
could for example comprise a strip of nylon material. It is
preferred that a winch is connected to the inner edge of a recess
provided within a floor extension of the larger modular unit, and
that the smaller unit 169 in pulled on the bearers using the winch.
By bolting to the larger unit the bearers can be advantageously
used to provide a guide. The system is preferably able to be
installed by two or three relatively unskilled persons.
[0105] Another advantage of the approach is considered to be that
it allows one to relatively maximise the floor area of the house.
The applicant considers that such a design in combination with a
modular roof system could possibly give a substantial additional
effective floor space in some embodiments. . This is considered to
allow for the design of more generous spaces which contribute to
the overarching goal of creating a home that looks and feels like a
site built house. Kitchen and bathroom facilities are centrally
located on a floor extension rather than in the main chassis.
During transportation, the relatively empty chassis of the larger
unit can be advantageously used to transport other material such as
roofing panels. This provides several advantageous assembly aspects
on site.
[0106] Referring to FIG. 24, there is shown a building construction
162 according to a further preferred embodiment of the present
invention. The building construction 162 comprises a body portion
164 having an upper structure 166 and a lower structure 168. The
lower structure 168 is advantageously adapted provide a water
compartment 170 that is adapted to be emptied to provide the lower
structure 168 with sufficient buoyancy to lift the body portion 164
in flood conditions.
[0107] The water compartment 170 comprises a symmetrical
arrangement adapted to accommodate a plurality of footings 172
extending therethrough and to allow the building to be formed using
two ISO certified containers. The water compartment 170 is fitted
within the lower structure 168 so as to form part of the lower
structure 168 and extend around along the boundary thereof.
[0108] The building construction 162 includes a vertical guiding
system 174 that is adapted to guide the body portion 164 up and
down during flood conditions. The vertical guiding system 174
comprises four guiding members 176 that are adapted to guide the
body portion 164 up and down.
[0109] The building construction 162 is considered to be
particularly advantageous for use in floodplain areas that are
subject to flooding. Generally where houses are formed from ISO
complaint shipping containers they would otherwise be washed
away.
[0110] In the embodiment the building construction 162 is provided
by positioning the roof and flooring extensions relative to two
prefabricated units and providing a flotation arrangement beneath
the floor extensions.
[0111] Referring to FIG. 25 there is shown a building construction
178 according to a further preferred embodiment of the present
invention. The building construction comprises a body 180 provided
by two transportable modules 182 (as previously discussed) where
each module 182 is adapted to be provided as an ISO shipping
container, when in a transport condition. Advantageously the
modules 182 can be assembled from the transport condition to
provide a building 184, in an extended condition. As shown in FIG.
25, the building 184 has a floor area 185 about three times the
combined horizontal area of the bases of modules 182, when
assembled in the transport condition. Advantageously the building
construction 178 further includes a panel system 186 comprising a
plurality of interchangeable panels 188 allowing the building 184
to be provided with different facade layouts suited to different
site orientations and other conditions.
[0112] The building system is considered to be particularly
advantageous as it allows the provision of a building formed from
ISO certified shipping containers where the building is able to be
desirably adapted by builders to suite the site orientations.
Owners can also advantageously decide where to position windows,
doors as well as internal walls.
[0113] Similarly to the previous embodiments described, the
building body 180 as assembled includes a floor portion 190 that
forms part of the sides of the modules 182 when the modules 182 are
provided in the transport condition. The floor portion 188 forms at
least part of the floor area 184 in the building body.
Advantageously the interchangeable panels 188 are arrangeable,
around the boundary of the floor area 185 to provide the different
facade layouts.
[0114] As shown in FIG. 25, the panel system 186 includes a wall
panel 194, a high window panel 196, a medium window panel 198, a
full window panel 200, a door panel 202 and a sliding window double
panel 204. Each of the panels of the panel system 186 is
advantageously of the same width apart from the sliding window
double panel 204 which is twice the standard width.
[0115] Advantageously by providing a modularised construction with
the panel system, mass manufactured container type houses are
considered to be able to be readily manufactured. Different
positions of facade and internal layouts can be readily
provided.
[0116] As shown in FIG. 26, the floor area 185 is substantially
square comprising a width 206 of approximately 6 standard panel
widths and height 208 of approximately 6 standard panel widths 206.
This is considered to be advantageous.
[0117] FIG. 27 shows the wall panel 194 in cross section.
Advantageously the wall panel 194 is provided with an extension 210
and an abutment 212. The abutment 212 is provided as a lower
surface for bearing against the floor portion 190. The extension
210 extends from the front of the abutment 212 downwardly past the
front face 214 of the floor portion 190 as shown in FIG. 27. This
serves to advantageously assist with weatherproofing the join
between the wall panel 194 and the floor portion 190. The extension
is preferably longer than 10 cm. In the embodiment the extension is
about 30 cm long which also serves to advantageously hide water
tanks provided beneath the floor portion 190.
[0118] The wall panels of the panel system 186 are hung at the top
and then attached with screws along the sides and the bottom for
the pressure seals to be sufficiently watertight.
[0119] In addition in the completed unit the are no cables in the
exterior wall panels, all the power and plumbing runs through the
main floor structures and the centre chassis. Floor boxes are used
rather than standard wall mounted outlets) to provide power outlets
to each room.
[0120] As detailed above, several preferred embodiments are
considered to provide a number of systems and methods that
advantageously: [0121] (i) Provide room areas having an improved
feeling of spaciousness and comfort in a building constructed using
prefabricated ISO standard container modules, where the building is
still relatively readily manufactured and installed. [0122] (ii)
Provide buildings, constructed using prefabricated ISO standard
container modules, having advantageous rain capture and
waterproofing capabilities while still being relatively readily
manufactured and installed. [0123] (iii) Provide ISO standard
container modules having prefabricated fold out floor extensions,
where during construction, the containers are placed side by side
to provide a building of advantageous size and the building is able
to receive a building module. [0124] (iv) Provide systems having
one or more containers each with a floor portion where the floor
portion can be folded to triple the floor space. [0125] (v) Provide
a building constructed using prefabricated ISO standard container
modules with advantageous flood protection capabilities. [0126]
(vi) Provide systems formed from at least one ISO shipping
container module having a plurality of panels that allow the final
building to be provided with different facade layouts suited to
different site orientations and other conditions.
[0127] In terms of the FIGS. 28 to 45: FIG. 28 shows an exploded
perspective view of one embodiment of a building; FIG. 29 shows
steps of one embodiment of a method of erecting the building of
FIG. 28 in accordance with an aspect of the invention; FIG. 30
shows a site with screw piles installed; FIG. 31 is a perspective
view of one embodiment of two units for a building, in accordance
with another aspect of the present invention, in collapsed mode and
received by the screw piles; FIG. 32 shows one of the units with
roof extensions swung up; FIG. 33 and FIG. 34 show base extensions
swung down into respective extended positions; FIG. 35 shows the
units with a sub unit disposed therein and columns installed over
the base extensions; FIGS. 36 and 37 show the roof extensions in
respective extended positions; FIG. 38 shows the unit with outer
panels installed; FIG. 39 shows the building in a final or near
final form; FIG. 40 shows an example of a cap which may form part
of the unit of FIG. 31; FIG. 41 shows an example of a hinge that
has more than one degree of freedom which is a part of the units of
FIG. 31; FIG. 41 shows an example of a vessel in the building of
FIG. 28; FIG. 43 shows various embodiments of exterior panels in
front of a building they may be fitted to; and FIGS. 44 and 45 show
one embodiment of a collapsible wall in a collapsed and an extended
mode respectively.
[0128] As shown in FIG. 28 an exploded perspective view of one
embodiment of a building is generally indicated by the numeral 312.
In the embodiment, a considerable fraction of the building 312 is
manufactured within a controlled factory environment, that is it is
prefabricated. This reduces the amount of skilled labour and time
required onsite.
[0129] The building 312 is delivered as one or more units in a
collapsed state. In the collapsed state the building 312 has an
external form commensurate with a shipping container, such as an
ISO shipping container. Another label for a shipping container, in
the context of this document, is an intermodal container. For
example, the base may have the same footprint as the base of an ISO
shipping container, the roof may also have the same width and
length as the roof of an ISO shipping container, and the side walls
may also have the same width and length as corresponding side walls
of an ISO shipping container. The external form of the collapsed
unit may, in some alternative embodiments, be commensurate with a
non ISO container standard. The United States often uses longer
units at 48 ft (14.63 m) and 53 ft (16.15 m). Some European
containers are about 2 inches wider at 2.5 m (8 ft 2.4 in) to
accommodate Euro-pallets. Australian RACE containers are also
slightly wider to accommodate Australia Standard Pallets.
[0130] The unit, in this particular embodiment, is not a shipping
container but has been constructed to take certain features of a
shipping container so that it can be transported over an intermodal
freight transport system which may comprise, for example, a
container ship, a container train, a truck, and specialized
container handling equipment such as a portainer. In another
embodiment, however, the unit is a shipping container that has been
suitably modified.
[0131] In a particular embodiment, the outer form of the unit is
commensurate with a high cube shipping container. High cube
containers have a width of around 2.44 m (8 feet), and a height of
2.89 m (9.5 feet). High cube containers are available in lengths
of, for example, 10, 20, 30 or 40 feet. The length of the unit in
this, but not necessarily all embodiments, is 20 feet.
[0132] The building 312 is be assembled by extending the unit
onsite, typically in a few weeks by an owner/builder, or by an
experienced construction crew in a matter of days.
[0133] FIG. 29 shows the steps of one embodiment of a method of
erecting the building 312 from one or more units and a sub unit. In
a first step, one or more units (in this example 2 units) such as
units 310,311 for the building 312, and a sub unit 374
are-delivered to a site on which the units 310,311 and thus the
resulting building 312 is to be located. The units 310,311 are
substantially identical, but do not need to be, and have dimensions
which are commensurate with a shipping container, such as an ISO
shipping container. In this embodiment, the units 310,311 have
external dimensions commensurate with a high cube shipping
container which is higher than "standard" . shipping containers.
The corresponding building thus has a relatively high roof and
relatively more internal volume than that which can be achieved
using lower shipping containers. The units 310,311, because they
have dimensions commensurate with a shipping container, may be
handled and transported using the existing infrastructure for
.handling and transporting shipping containers. In the embodiment
of the method shown in FIG. 29, the units 310,311 are delivered on
a B-triple truck which is configured to carry ISO shipping
containers. The B-triple truck also carries and delivers the sub
unit 374 which is to, be located in the units 310,311. Typically,
the sub unit 374 has external dimensions which are also
commensurate with a shipping container, but a shipping container
smaller than that corresponding to the unit 10 (typically lower but
having the same footprint). The sub-unit external dimensions may be
commensurate with an ISO shipping container.
[0134] In step 2, caps such as 374 are removed from the ends of the
units, and then the units 310,311 are positioned end to end upon
the site by, for example, a crane that is a part of the truck. In
this case, the units 310,311 are located on a plurality of columns
360 (as shown in FIG. 29) each having the form of a screw pile, for
example. The screw piles are typically installed on the site before
the units 310,311 and sub unit 374 are delivered.
[0135] In the following, the method will be explained further with
reference to unit 310, although it is to be understood that similar
steps may be performed with unit 311.
[0136] As shown in step 2, the unit 310 has a rectangular roof
extension 18 folded down to form a sidewall but which may be
extended to form an extension of the rectangular roof 316 of the
unit 310. During transport, the roof extension 318 is fastened down
in a collapsed position by clamps, cables, or ties for example.
Before the roof is swung up it is released.
[0137] When the roof extension 318 is swung up into an elevated
mode, as shown in step 3, rectangular base extension 320, which may
form an extension of a rectangular base 314 of the unit 310 when
folded down, is revealed. The base extension 20 is fastened during
transport. When it is to be swung down, the base extension 20 is
first released.
[0138] As shown in step 4, the base extension 320 is swung down to
form a larger floor area than that provided by the base 314
alone.
[0139] In step 5, the sub unit 374, which in this example has a
form commensurate with a 20 foot ISO container, is disposed within
the one or more units. In this example, the sub-unit is not a high
cube container. The sub unit 374, in this embodiment, may be a bath
and/or a kitchen and may have all of the plumbing and other
services in place. The sub-unit may have one or more doors, for
example opening into the kitchen and/or bathroom.
[0140] In step 6, the roof extension 18 has been swung down from
the elevated mode into an extended mode.
[0141] In step 7, panels are placed around the periphery of the
extended unit 310, the panels being, for example, wall panels,
doors and exterior windows. The panels may be all of the same
width, typically but not necessarily 1.2 m, and so the panels are
interchangeable. Generally, the use of panels is greatly simplified
when the roof extension is extended before the floor extension is
extended.
[0142] The various stages of the erection of another embodiment of
a building 312 are shown in more detail in the Figures. Similar
parts to those shown in FIGS. 28 and 29 have been similarly
numbered.
[0143] As shown in FIG. 30, a plurality of columns in the form of
screw piles such as 360 and 362 are first installed on the site.
FIG. 31 shows two units for a building abutted end to end, the
foremost unit indicated by the numeral 310 and the rearmost unit
indicated by a numeral 311. When the units are used as shown in
FIG. 32, the resulting building may be described as a modular
building. A vertical line indicates the boundary of the units 310,
311. A capping member is disposed over the boundary of the
respective roofs and/or roof extensions. The capping member, in
this embodiment in the form of a seal capping, is attached using
adhesives and/or fasteners. The units are shown in a collapsed mode
located on the piles 360. The unit 310 has opposing ends 348, 350
that are open, as does the unit 311. During transport, however, the
open ends 348, 350 may be capped, the additional cap structure
stiffening the unit for transport. With the caps installed, a unit
may have dimensions equal to an ISO shipping container, for example
a 20 foot long high cube. With the cap removed, the unit may be
slightly shorter than an ISO shipping container. The caps may be
removed on site, for example, and used as a component of the
building 132. FIG. 40 shows a front perspective view of an example
of a cap 374. The rear end of the cap is open and presents a cavity
into which an end of a unit may be received. The caps may be
configured to engage an intermodal container transport, such as a
container ship, by a pair of cooperating elements, each of the pair
of elements being located on one of the cap and the transport
respectively. When the elements are engaged, the unit can be
secured in handling and in transit. The element may, for example,
be a standard ISO mounting point 376 in the form a corner casting,
an element compatible with a twistlock (a fastening device used in
the container shipping industry). Any suitable fastening system may
be employed. The elements 376 may be located at one or more corners
of the cap 374 as for an ISO shipping container.
[0144] The unit 310 has a roof extension 318 which can adopt a
collapsed, an extended, or an elevated mode. In FIG. 31, the roof
extension 318 is shown in the collapsed mode (folded down). In this
embodiment, the roof extension 318 extends essentially the entire
span between the base and the roof to form an external wall of the
unit 310. In other embodiments, the roof extension does not extend
the entire span. The roof extension, in this embodiment, is
slightly smaller than an outer wall of a high cube container, and
in particular its width in this, but not necessarily all
embodiments, is around 2.8 m.
[0145] When the unit is in a collapsed mode, located behind the
roof extension 318 is a base extension 320. The base extension 320
can adopt either a collapsed mode or an extended mode. In FIG. 31,
the base extension 320 is shown in the collapsed mode. The base
extension has a width of 2.4 m. The base extension 320, in this but
not all embodiments, is of a lesser width than the roof extension
and thus does not extend the entire span between the base 314 and
the roof 316. This may provide space for, for example, a mechanism
such as a hinge connecting the roof extension to the unit. In the
extended mode the base extension 320 is an extension of the base
314; the top surfaces of the base and the base extension lie in the
same plane.
[0146] Because the roof extension is of greater width than the roof
extension the house is provided with an awning. The awning
advantageously improves passive thermal management making the house
more sustainable.
[0147] The roof extension 318 has a proximal edge 322 adjacent the
roof 316 and also a distal edge 324. When the roof extension 318
adopts the collapsed mode, the distal edge 324 is located adjacent
the base 314. In the extended mode, however, the distal edge 324 of
the roof extension 318 is elevated above the proximal edge 322 of
the roof extension 318, as shown in FIG. 28. The internal space is
generally higher than that provided by a container because the
distal edge is elevated. More height is provided on an outer edge
324 of the house than the interior under the roof 316. This
enhances the sense of space within the house, especially when
looking outwards beyond the distal edges of the roof extension.
Also, the inward slope of the roof extension causes rain that falls
on the house 312 to flow inwards where it can be centrally
collected and transported via a conduit to a water reservoir, such
as a tank located under the house.
[0148] As shown in FIG. 32, the roof extension 318 can, at least in
this embodiment, be swung up by greater than 180 degrees revealing
the base extension 320. The roof extension 18 is attached to the
roof by a hinge 342 shown in FIG. 28. The use of a hinge is
convenient as it supports half the weight of the roof extension as
it is swung around. A hinge also pre-aligns the roof extension with
respect to the roof and walls. Similarly, the base extension 320 is
attached to the base 314 by another hinge 344 shown in FIG. 32.
[0149] The roof extension in the elevated mode, as shown in FIG.
32, typically makes an angle of between 180-270 degrees with the
roof extension in the collapsed mode. The roof extension is
actually one of two roof extensions and in the elevated mode
respective distal edges of the roof extensions are brought
together. This is a relatively stable position, especially if the
extensions are fastened together, and expensive and cumbersome
equipment is not required to bring the extensions into the elevated
mode or hold them in this mode. In this mode, the roof extensions
are self supporting and conveniently out of the way during the
preliminary stages of erection.
[0150] As shown in FIG. 33 the base extension 320 may be swung down
into the extended position after the roof extension 318 has been
swung up.
[0151] The hinge 342 is configured so that the roof extension 318
can be swung either above or below the roof 316 and so adopt
various positions used during transport, construction and final use
of the building. This may be impossible using prior art
arrangements. A hinge that provides movement along a path rather
than around an axis may be used. That is, it may be advantageous to
use a hinge that has two or more degrees of freedom, such as for
example the double hinge shown in FIG. 42. The double hinge has a
first 380 and a second 382 pivot, the pivots being each connected
to a connecting member 383 common to the pivots. The first pivot
380 is attached to a first leaf 384 and the second pivot is
attached to a second leaf 386. Because the angle between each leaf
and the connecting member can be changed this double hinge has 2
degrees of freedom, unlike a standard hinge which has only one
degree of freedom. In use, the first leaf may be fastened to an
internal surface of the roof 16 adjacent an edge, and the second
leaf is attached to an internal surface of the roof extension 318.
When extending the roof extension, rotation around the first pivot
380 causes the second pivot 382 to swing out of the interior of the
unit and free of the roof. The roof extension can then be rotated
around the second pivot without interference from the roof. A hinge
with more than 2 degrees of freedom may be employed. A hinge having
one or more translational degrees of freedom may be employed. In
the present embodiment, the hinge is attached to external surfaces
of the unit, however it may be attached to internal surfaces of the
unit as described. This protects the hinge during transport etc,
and in this case the hinge does not extend beyond the dimensions of
the standard container the unit is modelled on.
[0152] The, unit 312 has a water proofing material over at least a
portion of a boundary between the roof and the roof extension. In
this embodiment, the material takes the form of a strip of water
proof membrane, such as a strip of PVC plastic sheet or a
bituminous sheet. In other embodiments, the water proofing material
may be a membrane applied as a fluid and allowed to set, such as
silicone.
[0153] Typically, the roof extension 318 is swung between the
collapsed and extended modes around the hinge 344 however it will
be appreciated that the roof extension need not be hinged. In
alternative embodiments, the roof 316 (or even the base 314) can be
detached from the unit and then reattached in the required position
or mode.
[0154] As can be seen in FIG. 33, the roof 316 is supported above
the base 314 by a plurality of posts 346 extending between the base
314 and the roof 316. The posts 346 may be, for example, steel tube
of a square cross sectional profile or in some embodiments, timber.
Generally any suitable material may be used for the posts 346. The
posts are offset from corners of the unit. This allows the
extensions to span the entire length of a unit in the collapsed
mode.
[0155] As shown in FIG. 33, the base extension 320, when in the
extended mode, sits on a plurality of columns, such as 362. The
column 362 may take the form of, for example, a screw pile, or
alternatively a brick pile with a concrete foundation. Generally
any form of suitable column may be employed. Screw piles, however,
may be rapidly deployed. The base extension (and indeed the base)
may have, for example, integral strengthening plates that engage
the columns.
[0156] As shown in FIG. 35, with the roof extension 318 swung up
and the base extension 320 swung down, the unit 310 may receive the
sub unit 374, which is in this embodiment has a length commensurate
with a 20 foot long ISO shipping container. In some embodiments,
more than one sub unit is disposed within the unit 310. The unit,
in this embodiment, comprises a kitchen and bathroom. The further
units may be, for example, bedrooms or studies or some other
specialised room.
[0157] The embodiments of the unit 310 and sub unit 374 shown are
each configured to receive one or more services such as a water
service, a gas service, an electrical service, a communication
service such as telephone or internet and a sewerage service. For
example, the unit 310 may come with one or more of an electrical
distribution board and electrical outlets, apertures for receiving
pipes and cables therethrough and ducts for pipes and cables; as
appropriate. The apertures may be capped for transport and handling
of the unit. An exterior service of the unit can comprise an
electrical connector for connection to the grid. The connector may
be recesses. Electrical wiring may be located within a floor
cavity, for example. Generally, no additional electrical work needs
to be done inside the house on site besides connecting the house to
an electrical supply such as an electrical grid. In this embodiment
the sub-unit 374 has a toilet, shower, stove, and oven all
connected to service conduits such as wires and pipes, for example,
within the unit.
[0158] The sub-unit of this embodiment has a base that is removed
prior to being disposed within the one or more units. In this case,
there is no step into the interior of the sub-unit from the
unit.
[0159] The sub-unit 374 has a vessel 388, shown in FIG. 41, adapted
to hold a thermal mass such as water, sand, or any suitable
material capable of storing heat. The vessel is typically adjacent
a side wall of the sub-unit and fixed to a wall of the sub-unit.
When the sub-unit is installed the vessel is ideally located near
or at the centre of the building. The unit is delivered with the
vessel empty. The empty vessel reduces the mass of the sub-unit
during transport and installation. In one form, the vessel is a
water tank of around 1,000 litres. Once the sub-unit is installed,
the may be filled with, for example, water delivered via a hose
connected to the water mains. Alternatively, sand, soil etc. may be
used, possibly sourced from the site. The thermal mass may help
stabilise the temperature within the building providing a better
interior climate without unnecessary transport of the mass.
[0160] As can be seen in FIG. 35, a plurality of columns, in this
embodiment in the form of steel posts 376, are erected above the
base extension 320. The posts such, as 376 are located over
respective screw piles. The roof extension 318 is then swung down
into the extended mode to rest upon the columns 376 as shown in
FIG. 36. The extensions may have integral strengthening plates that
engage the columns. The roof extension in the extended mode makes
an angle of 50-135 degrees with the roof in the collapsed mode.
[0161] As shown in FIG. 36 walls are disposed within the unit. At
least one of the walls 412 is a collapsible wall that is
transported in a collapsed mode (FIG. 44) and after being installed
adopts an extended mode (FIG. 45). The wall has first 414 and
second sheets 416 of material. A structure 418 is attached to the
first and second sheets. The structure, at least in this
embodiment, has a hinge although any suitable equivalent structure
such as a joint may be used. In this embodiment, the structure
actually has two double hinges 418. The double hinge has first and
second leaves, the first leaf being attached to the first sheet and
the second leaf being attached to the second sheet. The double
hinge is located between the sheets. The sheets are relatively
closer (say, 100 mm rather than 300 mm spacing) when the structure
is in the collapsed mode than the extended mode. Once expanded,
material such as an insulating material may be disposed in the
space between the sheets.
[0162] FIG. 38 shows the building with outer wall panels installed.
The panels are interchangeable to adapt to site specifications and
orientation. Because the outer walls are panels, cladding materials
can be exchanged as required. For example, the cladding material
may be fibre cement, timber, metal sheet, plastic or the like.
Because, in this embodiment, the outer walls are hung, they have
improved water proofing compared to outer walls attached via hinges
to the roof and/or base and which can be swung out on the hinges.
The load bearing features of the building 312 are columns 376. The
outer walls are self supporting, making the final structure
relatively easy to build and significantly lighter.
[0163] The base extension may have a proximal edge adjacent the
base and a distal edge. The distal edge is, in this but not
necessarily all embodiments, configured to receive a respective
edge of a panel. In this particular embodiment, the distal edge is
configured to engage the panel by a pair of cooperating elements,
each of the pair of elements being located on one of the distal
edge and panel respectively. The cooperating elements may comprise
a pin configured to be located in a corresponding recess. In
another embodiment, however, the cooperating elements may comprise
a protruding rib configured to be located in a corresponding slot.
Generally, any suitable engaging elements may be employed. It may
be preferable, in some embodiments, to have the male element, such
as a pin or rib, located on the panel. This is because a male
element located on the distal edge of the base extension would be
vulnerable to snagging and/or damage as the building is erected. A
male element on the panel is afforded some protection by virtue of
the adjacent structures, most notable a downward projecting flange
408 shown in
[0164] FIG. 43. The panel may comprise, for example, at least one
of a window, a wall panel and a door.
[0165] FIG. 43 shows various embodiments of the exterior panels
indicated by the numerals 390 to 400. Panel 390, for example, has a
first end 402 and a second end 404 that is spaced apart from the
first end 402. A surface 406 is disposed between the ends. The
surface may be, for example, the outer face of cladding, a surface
of a door, a window, a double sliding window, sliding doors etc. As
best seen in panel 400, the panels each have a flange 408 parallel
to the surface and extending away from one of the ends that it is
attached to. The flange has a surface which is adapted to be an
exterior surface. For example, the exterior surface may be painted
or treated metal or timber, plastic etc, and can withstand the
weather and/or sun. The flange 408 is substantially in the same
plane as the surface 406. The flange may comprise an insulating
material which covers the edges of the base and/or base extensions.
Alternatively or additionally, an insulating material, such as a
glass fibre mat, may be disposed between the flange and the base.
This is advantageous when the base and/or base extension is
fabricated of a thermally conductive material such as steel which
would normally act as a thermal conduit between the edges of the
base/base extension and the interior of the unit. The flanges may
also aid in waterproofing the structure because they may terminate
at or below the bottom of the base extension. Located behind the
flanges are the one or more elements that cooperate with
corresponding elements on the distal edge of the base
extension.
[0166] FIG. 38 shows the building in a final or near final form. A
vergeboard (or Bargeboard) 368 has been installed at an end of the
unit above the end panels 372. The verge board comprises material
of high thermal resistance, such as glass fibre matting, air blown
plastic such as Styrofoam, an analogue of these or any other
suitable material. Preferably a biodegradable insulating material
is used. One or more glass elements 370 are installed above the
side wall panels 336,338. Typically, the glass elements each
comprise glass panels of high thermal resistance, such as double
glazing, low emissivity glass, or even vacuum glazing.
[0167] The final building 312, such as that shown in FIG. 38, may
not have any reminiscence to a shipping container.
[0168] Typically, embodiments of the unit 310 are configured to
receive at least one solar collector such as a photovoltaic panel
or solar hot water heater. The roof or roof extensions may have
mounts 374 attached or formed therein ready to engage a solar
collector or a solar collector supporting member. In the present
embodiment, mounting plates 374 (FIG. 28) are fixed to an exterior
top surface by an adhesive such as a 2-part epoxy or cyanoacrylate
adhesive. The use of an adhesive is preferable to the use of
mechanical fasteners, such as screws, which may penetrate one or
more apertures formed in the roof. The apertures may provide a
conduit through which water or another substance may enter the
interior of the unit, which is generally undesirable. The apparatus
may be starting points for corrosion. The mounting plates may be
fabricated of aluminium, for example, but any suitable material may
be used. Alternatively or additionally, one or more exterior wall
panels such as 390 may one or have mounts such as 374 to engage a
solar collector or a collar collecting supporting member. In
another embodiment, a wall panel may have an integrated solar
collector. The solar collector may be installed when the building
is in a final or near final condition.
[0169] Thus in one aspect of the invention there is provided a unit
for a building, the unit comprising: a base; and a roof supported
above the base.
[0170] The unit may be prefabricated in a factory and form at least
part of a prefabricated or modular building. Mass production
techniques may be employed to reduce costs and construction time.
Because units from the factory may be similar or identical
economies of scale may be realised reducing costs. A quality, for
example one or more of energy rating, sustainability of the
materials used, or build quality, of the unit may be greater and
more certain when produced in a controlled environment typical of a
factory.
[0171] In embodiments, the unit comprises a roof extension, having
a collapsed mode and an extended mode, in the collapsed mode a
surface of the roof extension is also an external side surface of
the unit, and in the extended mode the roof extension is an
extension of the roof. The roof extension in the extended mode may
make an angle of 50-135 degrees with the roof extension in the
collapsed mode. The roof extension has a proximal edge adjacent the
roof and a distal edge that is, in the extended mode, elevated
above the proximal edge.
[0172] The collapsible unit may be easily transported in the
collapsed mode and still provide significant building space in the
extended mode. The distal edge being elevated above the proximal
edge is desirable for architectural reasons, including giving more
internal space and a greater sense of openness when looking outward
from within the building. Without the elevated distal edge the
building may feel unacceptably confined to a person, who may even
experience claustrophobia.
[0173] The roof extension also may have an elevated mode wherein
the distal edge of the roof extension is located over the roof. The
roof extension in the elevated mode may make an angle of 180-270
degrees with the roof extension in the collapsed mode. The roof
extension may be one of two roof extensions. In the elevated mode
respective distal edges of the two roof extensions may be brought
together.
[0174] When the roof extensions are in the elevated mode they are
conveniently out of the way during work performed at the level of
the base. The roof extensions are less likely to be damaged while
in the elevated mode during the work. The extensions may be
substantially self supporting when the respective distal edges are
brought together, reducing the need of building
tools/equipment.
[0175] In one embodiment, in the collapsed mode the roof extension
extends at least in part between the base and the roof. The roof
extension when in the collapsed mode may extend between the base
and the roof.
[0176] A roof extension that extends between the base and the roof
may form a superior barrier to external interference such as from
bumps, moisture etc. during transport.
[0177] In preferred forms, the roof extension is pivotally attached
to the roof. The roof extension may be attached to the roof via a
hinge such that the roof extension can be swung above and below the
roof.
[0178] Preferably, the roof extension is swung between the
collapsed, extended and elevated modes around the hinge. The hinge
has more than one degree of freedom. The hinge may be a double
hinge.
[0179] Preferably, the roof extension is configured to receive at
least one solar collector. Retrofitting buildings with fittings to
engage a solar collector may be more expensive than including the
fitting during fabrication of the unit. Ad hoc installation may
cause inadvertent d age to the building, for example if apertures
for fasteners need to be made.
[0180] Preferably, the unit comprises a water proofing material
disposed at least a portion of a boundary between the roof and the
roof extension.
[0181] In forms, the unit comprises a base extension having a
collapsed mode and an extended mode, in the collapsed mode the base
extension extends at least in part between the base and the roof,
and in the extended mode the base extension is an extension of the
base. The base extension when in the collapsed mode may extend only
in part between the base and the roof. The base extension may have
a proximal edge adjacent the base and a distal edge. The distal
edge may be configured to receive a respective edge of a panel. The
distal edge may be configured to engage the panel by a pair of
cooperating elements, each of the pair of elements being located on
one of the distal edge and panel respectively. The cooperating
elements may comprise a male element, such as a pin, configured to
be located in a corresponding female element, such as a recess.
Alternatively or additionally, the cooperating elements may
comprise a protruding rib configured to be located in a
corresponding slot. The panel may comprise at least one of a
window, a wall panel and a door.
[0182] A collapsible base provides easier transport while allowing
significant floor space. The use of interchangeable panels may
greatly extend the flexibility of the design of the building. The
panels may aid in waterproofing the building, especially compared
with, for example, wall panels that are hinged to the building.
[0183] In forms, the roof is supported above the base by a
plurality of posts extending between the base and the roof. Each
post may be offset from a respective corner of the base. The posts
may each comprise a steel tube.
[0184] Offset posts may not interfere with the roof extension
and/or base extension providing more design freedom and may
maximise roof and/or base extension area. When the base extension
and the roof extension are in respective collapsed modes, the roof
extension forms an external side surface of the unit behind which
the base extension is disposed.
[0185] The external side surface may be a relatively tough surface,
such as steel, which protects the base extension and other p
internal of the unit during transport.
[0186] In one form, the base extension is configured, when in the
extended mode, to be supported by a plurality of columns. Columns
may provide a level structure on which the base and base extension
can be housed and reduce the ingress of moisture and/or pests into
the building.
[0187] One or more dimensions of the unit are commensurate with the
dimensions of a shipping container. When the roof and base
extensions are in respective collapsed modes, the unit may have the
dimensions of a shipping container. The shipping container may be
an ISO shipping container. The ISO shipping container may be a high
cube shipping container.
[0188] A unit which takes aspects of an ISO shipping container may
conveniently take advantage of the existing shipping and handling
infrastructure for shipping containers. Furthermore, the unit may
be configured to receive one or more services. The unit may
comprise conduits for the one or more services. At least one
service may comprise one or more of a water service, a gas service,
an electricity service, a communications service and a sewerage
service. The requirement for on site tradesmen may be thus
reduced.
[0189] In one embodiment, the unit comprises opposing ends that are
open. In one embodiment, an end of the unit is capped by a cap. The
caps may assist in sealing the unit against the ingress of moisture
etc: during transport. The caps may also provide engaging means for
the existing shipping transport and handing infrastructure to
engage, and may subsequently be removed on site without
compromising the design of the building. Removable caps provide
greater freedom to configure the ends of the building which may
otherwise be aesthetically unsatisfactory. The cap, which may be
fabricated from a strong material such as steel for transportation
and handling considerations, may be used as part of the building,
instead of being unnecessarily used as ends of the building.
[0190] In forms, the unit is configured to be supported on a
plurality of columns. The unit may be configured to receive within
it a sub unit having dimensions commensurate with a shipping
container. The sub-unit may have external dimensions of a non-high
cube shipping container. The sub-unit may comprise a vessel adapted
to contain a thermal mass. The sub unit may have a complete kitchen
and/or bathroom, for example, reducing the requirements for
tradesmen on site. The use of a thermal mass may stabilise the
internal temperature of the building. The vessel may be installed
when empty and subsequently filled, with water from a pipe for
example, which makes handling easier. Thermal masses are typically
between 1000 and 10,000 kg and are thus difficult to handle. A
sub-unit the height of a standard ISO shipping container may fit
within units having the height of a high-cube container.
[0191] In a second aspect of the invention, there is provided a
sub-unit adapted to be received by a unit in accordance with the
first aspect of the invention. In embodiments, the sub unit
comprises a door. The sub-unit may comprise one or more services.
The sub-unit may comprise a bathroom. The sub-unit may comprise a
kitchen. The sub-unit may comprise a vessel adapted to contain a
thermal mass. The vessel may be a water tank.
[0192] In another aspect of the invention there is provided a
method of erecting a building, the method comprising the steps of:
providing a unit in accordance with the first aspect of the
invention with the roof extension in the collapsed mode; and
causing the roof extension to adopt the respective extended
mode.
[0193] In an embodiment, the method comprises the step of causing
the roof extension to adapt the elevated mode. In an embodiment,
the method further comprises the steps of causing the base
extension to adopt the respective extended mode. A distal edge of
the base extension may receive a panel after the base extension is
caused to adopt the extended mode. In an embodiment, the method
comprises the step of disposing one or more posts between the roof
extension and the base extension. Most or all of the load of the
roof extensions may be taken by the posts, instead of the panels
for example, which provides considerable freedom in design. For
example, the panels need not be load bearing and their other
aspects, such as visual appearance, may be thus accentuated.
[0194] In an embodiment, the method comprises the step of locating
the unit on a plurality of columns. The method may comprise the
step of installing the plurality of columns. In an embodiment, the
method comprises the step of disposing a sub unit within the unit.
The sub-unit comprises a bathroom and/or kitchen.
[0195] In an embodiment, the step of causing the roof extension to
adopt the respective extended mode occurs before the step of
causing the base extension to adopt the respective extended
mode.
[0196] In another aspect of the invention, there is provided a
method of erecting a building comprising the step of, during
erection, disposing a vessel adapted to contain a thermal mass in
the building. In an embodiment, the vessel, when disposed in the
building, is empty. The method may comprise the step of disposing
the thermal mass in vessel. The vessel may be adapted to hold
water. The step of disposing the thermal mass in the vessel may
comprise filling the tank with water. In an embodiment, the vessel
is part of a sub-unit in accordance with the second aspect of the
invention and the step of disposing the vessel in the building
comprises the step of disposing the sub-unit in the building. In an
embodiment the method comprises the step of providing a unit in
accordance with the first aspect of the invention and extending the
unit.
[0197] According to yet another aspect of the invention there is
provided an exterior panel for a building, the panel comprising: a
first end and a second end spaced apart from the first end; a
flange attached to one of the ends and adapted to engage an edge of
either one of a base of a building and an extension of a base of a
building. The panel and particularly the flange may provide thermal
insulation, and may improve the water proofing of the building. In
an embodiment, the flange has a surface which is adapted to be an
exterior surface. In an embodiment, the flange is substantially in
the same plane as a surface of one of the ends. In an embodiment,
the flange comprises an insulating material. In an embodiment, the
panel is configured to engage the building by a pair of
co-operating elements, each of the pair of elements being located
on one of the building and panel respectively. In an embodiment,
the panel comprises a surface disposed between the ends. A corner
may be located directly behind the flange. The corner may be
adapted to receive an edge of the building. The flange may be
attached to one of the ends. The flange may be is parallel to the
surface disposed between the ends. In an embodiment, the flange is
configured to conceal the edge.
[0198] In another aspect of the invention there is provided a
collapsible wall comprising: first and second sheets of material; a
structure attached to the first and second sheets having an
extended mode and a collapsed mode, wherein the sheets are
relatively closer when the structure is in the collapsed mode than
in the extended mode.
[0199] The collapsible wall may be collapsed during, for example,
transport and storage but expanded when installed in the building.
In an embodiment, the structure comprises a hinge. The structure
may comprise a double hinge. The hinge may comprise first and
second leaves, the first leaf being attached to the first sheet and
the second leaf being attached to the second sheet. In an
embodiment, the structure is located between the sheets.
[0200] According to a further aspect of the invention there is
provided a unit for a building , comprising: a base; a roof
supported above the base; a roof extension having a collapsed mode
and an extended mode, in the collapsed mode a surface of the roof
extension is also an external surface of the unit and in the
extended mode the roof extension is an extension of the roof, the
roof extension having a proximal edge adjacent the roof and a
distal edge that is, in the extended mode, elevated above the
proximal edge.
[0201] In an embodiment, the unit comprises: a base extension
having a collapsed mode and an extended mode, in the collapsed mode
the base extension extends at least in part between the base and
the roof, and in the extended mode the base extension is an
extension of the base. In an embodiment, the roof extension also
has an elevated mode wherein the distal edge of the roof extension
is located over the roof.
[0202] In a further aspect of the invention there is provided a
modified shipping container comprising: a base; a roof supported
above the base; a roof extension having a collapsed mode and an
extended mode, in the collapsed mode a surface of the roof
extension is also an external surface of the unit and in the
extended mode the roof extension is an extension of the roof. In an
embodiment the roof extension has a proximal edge adjacent the roof
and a distal edge that is, in the extended mode, elevated above the
proximal edge.
[0203] Further advantages and preferred features will be apparent
from the drawings and a reading of the specification as a
whole.
[0204] It is to be recognised that the embodiments described may be
partly conceptual in nature, and that the applicant is developing
further arrangements that are more likely to be put into commercial
use.
[0205] It is to be recognised that various alterations and
equivalent forms may be provided without departing from the spirit
and scope of the present invention. This includes modifications
within the scope of the appended claims along with all
modifications, alternative constructions and equivalents. There is
no intention to limit the present invention to the specific
embodiments shown in the drawings. The present invention is to be
construed beneficially to the applicant and the invention given its
full scope.
[0206] In the present specification, the presence of particular
features does not preclude the existence of further features. The
words `comprising`, `including` and `having` are to be construed in
an inclusive rather than an exclusive sense.
[0207] It is to be recognised that any discussion in the present
specification is intended to explain the context of the present
invention. It is not to be taken as an admission that the material
discussed formed part of the prior art base or relevant general
knowledge in any particular country or region.
* * * * *