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WO2012012688A1 - Système et procédé de construction - Google Patents

Système et procédé de construction Download PDF

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Publication number
WO2012012688A1
WO2012012688A1 PCT/US2011/044960 US2011044960W WO2012012688A1 WO 2012012688 A1 WO2012012688 A1 WO 2012012688A1 US 2011044960 W US2011044960 W US 2011044960W WO 2012012688 A1 WO2012012688 A1 WO 2012012688A1
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WO
WIPO (PCT)
Prior art keywords
building
panels
wall
roof
ceiling
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2011/044960
Other languages
English (en)
Inventor
Kenneth G. Trascher
David Cain
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US13/703,085 priority Critical patent/US20130074424A1/en
Publication of WO2012012688A1 publication Critical patent/WO2012012688A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/34384—Assembling details for foldable, separable, collapsible or retractable structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/08—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
    • E04H1/02—Dwelling houses; Buildings for temporary habitation, e.g. summer houses

Definitions

  • 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.
  • 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.
  • locations include, without limitation, areas which have been ravaged by war, storms and other disasters (hereinafter “disaster areas”).
  • disaster areas areas which have been ravaged by war, storms and other disasters.
  • construction materials, tools and skilled labor are generally unavailable, yet it is precisely in such areas where at least some initial building is urgent needed so that the process of recovery can begin.
  • the building system and method of the present invention are a significant improvement over existing building systems used in disaster 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.
  • phase 2 a wooden floor is built under the existing tent.
  • 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.
  • 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.
  • 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.
  • RLBs relocatable buildings
  • An advantage of the RLBs is that they can be shipped in a flat configuration of 4 units.
  • 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.
  • 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.
  • 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.
  • the container 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.
  • 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 x 2440 mm), so that there is no cutting or fitting required on site for said panels.
  • 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.
  • 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 x 9756 mm x 2440 mm).
  • the major building components of the invention are preassembled and modularized, requiring no measuring or cutting.
  • 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.
  • 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.
  • 6 identical- sized wall panels 8 identical ceiling panels, 9 identical roof trusses and 8 identical roof panels.
  • 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.
  • the wall panels 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.
  • 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.
  • 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.
  • 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.
  • the preferred building system of the present invention provides the following features and benefits:
  • Complete system uses the above structure and adds standing seam sheeting for exterior walls and roof; cement fire board for interior wall, 1 hour fire rated steel door.
  • 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.
  • 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.
  • FIG. 1 is a perspective view of the preferred building of the invention.
  • 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.
  • FIG. 3 is a top view of the container, absent its top, showing the building components, materials and tools nested therein.
  • FIG. 4 is a partial, perspective view of the inside of the container depicted in Figure 3.
  • FIG. 5 is a perspective view depicting the erection-in-progress of the building walls in accordance with the invention.
  • FIG. 6 is a side elevational view of the outer surface of a preassembled modular wall panel, covered with insulation.
  • FIG. 7 is a side elevational view of the finished inner surface of a preassembled modular wall panel.
  • 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.
  • FIG. 9 is a partial, perspective view depicting the erection of ceiling panels placed on and supported by walls of the building.
  • 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.
  • 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.
  • FIG. 12 is a side elevational view of a preassembled modular roof truss in accordance with the preferred embodiment of the invention.
  • 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.
  • FIG. 14 is a top view of a preassembled, modular roof panel in accordance with present invention.
  • FIG. 15 is a partial, perspective view depicting the placement-in-progress of roof cladding on a roof panel in accordance with the invention.
  • FIG. 16 is a perspective view of the building of the present invention, nearing completion, with the wall-cladding not yet fully complete.
  • FIG. 17 is a cross sectional view of the entire, completed building, taken along lines 17-17 of
  • FIG. 18 is a plan view of the outer surface of a preassembled, modular ceiling panel without any insulation, showing its framing members.
  • FIG. 19 is a plan view of the finished inner surface of a preassembled, modular ceiling panel.
  • 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 Figure 2 as shown.
  • 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.
  • Figure 1 generally depicts the finished building 10 of the present invention in its preferred embodiment.
  • Figure 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.
  • 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.
  • Figures 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.
  • the building components preferably include a plurality of preassembled, modular wall panels 20, as best depicted in Figures 5, 6 and 7.
  • each wall panel 20 is approximately 16 feet long and 8 feet high, more preferably 16' 2" by 8 ⁇ ", and fits comfortably inside a 20-foot ISO container 12 as shown in Figures 3 and 4.
  • 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 Figure 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).
  • 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.
  • hat omega 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.
  • 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.
  • each wall panel 20 has a finished inner surface 26 and an outer surface 28, as best depicted in Figures 7 and 6.
  • Wall framing members 24 are preferably provided with openings 23 along their lengths, as depicted in Figure 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.
  • preassembled wall panel 20 is preferably covered with wall insulation 30, as shown in Figure 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.
  • 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.
  • 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.
  • 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 Figure 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.
  • 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.
  • building 10 of the present invention is not limited to a 16-foot by 32-foot rectangular configuration.
  • 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.
  • 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.
  • the wall panels 20 may be placed on and supported by preassembled modular floor panels 110, depicted in Figure 21, which may be shipped in and with container 12.
  • 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.
  • rear wall 34 and right side wall 38 have already been stood upright.
  • 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").
  • screws which are sometimes referred to in the industry as "grabber” screws (hereinafter “screws").
  • screws Such fastening means are among the building components transported in container 12 of the present invention.
  • Figure 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.
  • the front wall 32 shown in Figure 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.
  • the perimeter of the building is established once all the wall panels shown in Figure 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.
  • 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.
  • 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.
  • 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 Figure 4.
  • 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 Figure 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).
  • 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.
  • 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 Figure 11.
  • 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.
  • 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.
  • 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.
  • 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 Figures 9 and 10, with the finished inner surface 46 of each ceiling panel 40 facing downward and toward the inside of the building.
  • 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.
  • 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.
  • 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 6 land an apex 63, as shown in Figures 11 and 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 Figures 3 and 4.
  • 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); and stud depth of 3.50 inches (89 mm).
  • 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.
  • 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 Figures 10 and 11.
  • 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.
  • 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.
  • the building of the present invention is not limited to the preferred roof pitch shown in Figure 17, which is approximately l-rise-to-3.5-run, more preferably 14°.
  • 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.
  • 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.
  • 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.
  • each roof panel 70 is approximately 8 feet wide and 9 1 ⁇ 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 Figures 3 and 4.
  • 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).
  • 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.
  • 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 trasses 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 Figures 13 and 15.
  • each roofing panel 70 is 8 feet and 1.16 inches wide, and 9 feet and 7.23 inches long.
  • 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 Figure 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in Figure 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.
  • 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.
  • 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.
  • 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.
  • 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 Figure 5.
  • the 5 mm lips to the inside of the c-shaped channel are notched to permit the insertion and joining of channel sections.
  • 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.
  • 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.
  • the roof and wall cladding 80 and 90 is preferably shipped nested in sheets between roof panels 70 and ceiling panels 40.
  • the sheets of roof and wall cladding 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, Colorado.
  • 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 Figure 20.
  • the profile gives the material desired rigidity against bending, and the material is cut into desired sheet lengths.
  • 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.
  • sheets of roof cladding 82 are placed on top of roof panels 70.
  • 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.
  • 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 Figure 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in Figure 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 Figure 1.
  • 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 Figure 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.
  • each sheet of front and rear wall cladding 94 will be in the shape of a trapezoid, as best shown in Figure 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 Figure 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 Figure 2.
  • 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 Figure 17. Accordingly, if building 10 for example has a width other than 16 feet and/or a roof pitch other than as shown in Figure 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.
  • 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.
  • 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.
  • corner flashing 147 Four pieces of corner flashing 147, shown in Figure 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.
  • each such floor panel 110 preferably includes 2 full sheets 1 12 of fiber cement wall board, as shown in Figure 21.
  • Each sheet 112 is preferably 4 feet wide, 8 feet long and 0.750 inches thick.
  • 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.
  • 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.
  • 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.
  • 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.
  • Each preassembled floor panel 110 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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. x 16 ft. perimeter edge of the supporting floor panels 1 10. 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.
  • 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.
  • the building includes, on all four exterior and interior corners, upper and lower sets of metal "L" brackets 130.
  • 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 Figure 20.
  • An interior corner trim piece 136 may also be provided at each interior corner of the building.
  • eight sets of "L" brackets, 16 carriage bolts, and 4 interior corner trim pieces are loaded and shipped in container 12.
  • 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.
  • a local source of electric power may be used to power the building.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

L'invention porte sur un système et sur un procédé pour la construction d'un bâtiment à partir de composants, de fournitures et d'outils qui sont transportés vers le site de construction désiré dans un conteneur d'expédition. Les composants de construction chargés et transportés dans le conteneur d'expédition comprennent des panneaux de paroi, des panneaux de plafond, des fermes de toit, des panneaux de toit, des feuilles de revêtement de toit et des feuilles de matériau de couverture pré-assemblés. Chaque composant pré-assemblé est dimensionné de telle sorte qu'aucune mesure ni aucune coupe de celui-ci n'est requise pendant la construction sur le site de construction, et chaque composant peut être porté manuellement sans la nécessité d'utiliser un dispositif de levage.
PCT/US2011/044960 2010-07-23 2011-07-22 Système et procédé de construction Ceased WO2012012688A1 (fr)

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US13/703,085 US20130074424A1 (en) 2010-07-23 2011-07-22 Building system and method

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US36714310P 2010-07-23 2010-07-23
US61/367,143 2010-07-23

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CN104091475A (zh) * 2014-07-17 2014-10-08 中国石油化工股份有限公司 移动式多功能教室
CN110158996A (zh) * 2019-06-04 2019-08-23 深圳市新天能科技开发有限公司 一种装配式被动式节能房屋及其建造方法

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US9085890B2 (en) 2011-05-05 2015-07-21 Rapid Fabrications IP LLC Collapsible transportable structures and related systems and methods
US20150132082A1 (en) * 2013-11-11 2015-05-14 Michael N. Goshi Pre-assembly of casework components in shipping container
US10196808B1 (en) * 2016-01-13 2019-02-05 Garrett B. Gibbs Building comprising prefabricated composite panels with rigid structural frame
US11377844B2 (en) 2018-09-05 2022-07-05 Matt James Clifton Collapsible dwelling
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US11574085B2 (en) * 2019-11-07 2023-02-07 Consulting Engineers, Corp. Method and system for identifying conflicts in a floor joist and wall panel vertical interface
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US20220025664A1 (en) * 2020-07-23 2022-01-27 Lifebox Portable enclosed-structure deployment system
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US20240141639A1 (en) * 2021-03-03 2024-05-02 Rohe Homes Ltd. Systems and methods for manufacturing anddeploying modular buildings
US20230058566A1 (en) * 2021-08-18 2023-02-23 Modeco Development LLC Apparatus utilized to construct modular homes
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CN104091475A (zh) * 2014-07-17 2014-10-08 中国石油化工股份有限公司 移动式多功能教室
CN110158996A (zh) * 2019-06-04 2019-08-23 深圳市新天能科技开发有限公司 一种装配式被动式节能房屋及其建造方法

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