AU2005201498B2 - A Construction - Google Patents

Description

00 0 oo r,

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant(s): Actual Inventor(s): Address for Service: Invention Title: Details of Associated Provisional Applications: Ashley Paul TALBOT Ashley Paul TALBOT FRASER OLD SOHN Patent Attorneys Level 6, 118 Alfred Street MILSONS POINT NSW 2061 A CONSTRUCTION Australian Provisional Patent Application No. 2004 901 879 Filed 8 April 2004 The following statement is a full description of this invention, including the best method of performing it known to us: Field of the Invention The invention relates to structures and, in particular, to a construction and a kit for use as a construction.

00 O The invention has been developed primarily with respect to habitable constructions 00 and will be described hereinafter with reference to this particular application.

However, it will be appreciated that the invention is not limited to this particular field of use.

S Background Art Home ownership in Australia has become significantly less affordable to those earning about the average national wage or less. This has occurred in within the last decade. Some of the factors contributing to the declining affordability include the scarcity of urban or suburban land for single dwelling residential construction. For example, it is not uncommon for potential homeowners to have a sufficient funding for the land but inadequate funding to construct a suitable dwelling.

Another contributing factor to the decreasing affordability extends to an under supply of skilled labour to be able to construct dwellings, as well as increases in building material costs. Dwellings are typically constructed using the conventional 'post and beam' of building construction method. This involves the erection of main corner posts prior to the installation of floor beams and bracing members which attach to the posts.

The method requires the locating of each main corner post footing to be positioned by survey. A concrete footing at each corner position is cast and each post is located on the footing, again by survey. Each main corner post is braced and fixed in a plumbed position temporarily and the floor beams are connected to the post, together with their braces. Each post is being re-plumbed and realigned and fixed accurately in its final position. Grout is added between the base of each main corner post and footing surface.

tV If this erecting procedure is not carried out to a sufficient degree of accuracy, the

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Obuilding will be constructed out of skew. The inherent problems of the post and beam construction techniques are the location of the posts at an accurate position with correct spacing between each post, the positioning of the posts square and in parallel S 5 with one another, and aligning and fixing the post plumb. These problems are the result of a construction sequence for the building which requires the corner posts, 00 typically a unwieldy component and the most difficult to set out accurately, to be Sinstalled first.

tf 10 Any inaccuracy in post and beam construction technique will have a compounding Seffect on the accuracy of the building as it is constructed. This problem is further worsened where a building is required to be constructed in a remote area or unusual building site, and where there is a limited availability of skilled labour and specialist tools, such as survey equipment.

Object of the Invention It is an object of the invention to provide a construction and a kit for use as a construction that will overcome or substantially ameliorate the deficiencies of the prior art, or to provide a useful alternative.

Summary of the Invention According to a first aspect of the invention there is provided a construction including: a substantially horizontal outer square frame spaced apart from or contiguous with the ground by a foundation post disposed at the midpoint of each outer frame side and at each outer frame corner wherein the foundation post extends a predetermined distance above the outer square frame, each outer frame side formed from at least two primary external beams each of a standard length; an inner square frame disposed within the outer square frame and in the plane thereof, each inner square frame side formed from a primary internal beam of the standard length wherein each corner of the inner square frame is connected to a midpoint of the outer square frame sides; a multipart connector configured to connect each primary external beam 0together to form an outer square frame side, the connector including an edge beam

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Sextending between the inner and outer square frames to provide a connection therebetween; and 00 5 a pair of stabiliser braces moveable between a first position wherein the braces are mounted to a temporary foundation post and extend downwardly therefrom to 00 temporarily support the temporary foundation post at each corner of the inner square frame and the edge beam level, and a second position wherein the braces are mounted between the foundation post and the end of the multipart connector edge beam at or tV 10 adjacent the connection with a corner of the inner square frame.

Preferably, the construction includes two or more outer square frames disposed in a side-by-side arrangement such that the outer square frames are connected together at at least one corner point and one midpoint of an outer frame side. More preferably, the foundation posts are each of the standard length.

In preferred embodiments, an end of each foundation post extends a predetermined height above the outer and inner square frames and support an upper outer square frame substantially parallel with the lower outer square frame, and wherein the foundation posts extend from the mid-points of the outer square frame and support the corners of an upper inner square frame with a multipart connector and the stabiliser braces disposed intermediate.

Preferably, the upper inner square frame supports a roof structure disposed thereover or an upper storey floor. More preferably, the lower inner square frame is configured to support a floor and the upper square frame configured to support a roof structure, and the upper and lower inner frames define a wall space therebetween wherein the frames are configured to detachably retain a plurality of planar wall, door and/or window in-fill panels around the inner frames, and wherein the upper and lower outer frames define a wall space therebetween wherein the frames are configured to detachably retain a plurality of planar wall, door and/or window in-fill panels around the outer frames.

ti Preferably, the primary external beams and primary internal beams are formed from

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O steel C-shaped cross-section and the foundation posts from steel square cross-section lengths, and the multipart connector edge beam includes a cleat disposed adjacent the inner square frame, the cleat configured for securing the corners of the inner square 00 5 frame thereto.

0 OO According to a second aspect of the invention there is provided a kit for use as a Sconstruction according to the first aspect of the invention, the kit including: 0 an outer square frames wherein each outer frame side is formed from at least t¢ 10 two primary external beams each of a standard length; 0 a plurality of foundation posts each of the standard length configured to support the outer square frame above the ground or contiguous therewith; an inner square frames wherein each inner square frame side is formed from a primary internal beam of the standard length, and where each corner of the inner square frame is configured for connection to a midpoint of the outer square frame sides; a plurality of multipart connectors configured to connect each primary external beam together to form an outer square frame side, the connector including an edge beam configured to extend between the inner and outer square frames to provide a connection therebetween; and a pair of stabiliser braces for each multipart connector, the stabilisers configured for movement between a first position wherein the braces are mountable to a temporary foundation post and extend downwardly therefrom to temporarily support the temporary foundation post at each corner of the inner square frame and the edge beam level, and a second position wherein the braces are configured for mounting between the foundation post and the end of the multipart connector edge beam at or adjacent the connection with a corner of the inner square frame.

It can therefore be seen there is provided a construction and a kit use as a construction that addresses the problems of prior art by constructing the floor frame of the module prior to installing the main corner posts. It can be seen that the invention advantageously provides a self aligning assembly that can accurately locate the main corner posts without initially requiring footings and without the need for surveying or ¢n temporary bracing. The invention also allows the construction to be added to without demolition of the initial constructions.

Brief Description of the Drawings 00 5 A preferred embodiment of the invention will now be described, by way of example only, with referenced to the accompanying drawings in which: 00oO FIG. 1 is an isometric view of a construction according to the preferred embodiment; SFIG. 2 is a top view of the construction of FIG. 1; tC 10 FIG. 3 is a perspective view of a multipart connector with a brace in a first Sposition in the construction of FIG. 1 FIG. 4 is a perspective view of the multipart connector of FIG.3 FIG. 5 is an interview of the multipart connector of FIG. 3 with the brace in the first position in-situ; FIG. 6 is a side view of the multipart connector of FIG. 3 with the brace in the second position; FIG. 7 is a perspective view and of part of an outer square frame corner of the construction of FIG. 1; FIG. 8 is and a perspective view of part of an outer square frame side of the construction of FIG. 1; FIG. 9 is a top view of a roof disposed on the construction of FIG. 1; FIG. 10 is it a top view of the construction of FIG. 1 in the form of the dwelling; FIGS. 11 to 20 are views of wall, door and window panels for use with the construction of FIG. 1; FIG. 21 is a plan view of a plurality of the constructions of FIG. 1 connected together; and FIG. 22 is another plan view of a plurality of the constructions of FIG. 1 connected together.

Detailed Description Referring to FIG. 1, there is shown an isometric view of a construction 1, with a top view shown in FIG. 2. The construction 1 includes a horizontally disposed outer t square frame 2 spaced apart from the ground by a plurality of the foundation posts 3 Sin the form of square section post in any material such as wood or hollow steel square Ssection of a standard post length.

00 5 The foundation posts 3 are disposed at each corner 4 of the outer square frame 2 and at the midpoint of each outer frame side 5. The foundation posts 3 each extend from 00 respective footings 16 the same distance above the outer square frame 2. Each square frame side 5 is formed from two primary external beams 6. Each primary external Sbeam 6 is formed from steel C-section of a standard length for suppliers of such 't 10 beams. A preferred standard beam length is 5.7 m.

The construction 1 includes in inner square frame 7. The inner square frame 7 is disposed within the outer square frame 2 and in the plane thereof. Each inner square frame side 8 is formed from a primary internal C-section steel beam of the same standard length as the external primary beams 6. Each corner of the inner square frame 7 is connected to a midpoint 5 of the outer square frame side.

A multipart connector 9 connects the inner square frame corners to the midpoint 5 of the outer square frame 2. The multipart connector 9 includes an edge beam 10 that extends between the midpoints 5 and the corners of the inner square frame. The connector 9 is configured to receive a foundation post 3 at a proximal end.

The multipart connector 9 includes a pair of stabiliser braces 11 made from steel right angled bracket at an obtuse angle. The braces 11 are movable between a first position wherein the braces 11 are mounted to a temporary foundation post 12 (not shown in FIG. 1) and extend downwardly therefrom to support the temporary foundation post 12 at each corner of the inner square frame 7 and the edge beams level. The temporary post 12 can be any post.

The stabiliser braces 11 are movable to a second position wherein the braces 11 are mounted between the foundation post 3 and the distal end of the multipart connector edge beam 13 at or adjacent the connection with a corner of the inner square frame 7.

in Each foundation post 3 extends a distance above the inner and outer square frames 6 Sand 2, and can be formed from multiple lengths connected end-on-end. The ends of Sthe posts 3 extending upwardly are used to support an upper outer square frame 14 and upper inner square frame 15. In this embodiment, the foundation posts extend 00 5 from the mid-points 5 to support the corners of the upper inner square frame 15 with a multipart connector 9 disposed intermediate.

00 The primary external beams 6 and the inner square frame sides 7 (primary internal Sbeam) are formed from C-section steel tubing of the same dimensions, including the IC 10 standard length, 5.7m in this embodiment. The foundations posts are of any standard Slength. It will be appreciated that the needed foundation post length is unpredictable on uneven ground unless prior surveyed. Thus, the top of the foundation posts 3 can be trimmed or docked above the upper outer square frame connection as desired.

Turning now to FIG. 3, there is shown is a perspective view of a multipart connector with the braces 11 in the second position (where only one brace can be seen) and with only part of an inner square frame corner attached. The brace 11 extends from the distal end 17 of the multipart connector 9 to attach to the foundation post 3 to support the two together. FIG. 4 shows two braces 11 each connected to a foundation post 3 and extending to the distal end of the edge beam 10. The inner square frame 7 is attached to the distal end 17 of the multipart connector 9 by means of an attachment cleat 18 and a brackets 19., as best seen in FIG. 3.

FIG. 5 is an end view of the multipart connector 9 and the braces 11 when in the first position. The braces extend from the temporary post 12 to attach or otherwise be secured to the ground. Spikes 20 or the like can be used. The multipart connector edge beam 10 is then levelled.

FIG. 6 is a side view of the multipart connector 9 with the brace in the second position and is mounted to the foundation post 3 at the distal end 17 of the multipart connector edge beam 10 adjacent the inner square frame corner.

t¢ FIG. 7 is a perspective a perspective view of part of an outer square frame corner of C the construction of FIG. 1. A pair of brackets 21 are used to support the outer square

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Sframe sides 6 together. A receiving bracket 29 is used to secure the multipart connector edge beams 10 to the foundation posts.

00 A similar arrangement of using pairs of brackets 21 is provided for the joining end-to- 00 end of the primary external beams at the midpoints 5 of each outer frame side.

SReferring to FIG. 9, there is shown a top view of a roof structure 22 disposed on the 10 construction 1. The roof 22 is constructed from a frame 23 mounted to the upper Sinner square frame. The roof also includes a plurality joist beams 24 connected to the upper inner and outer square frames with cleats 18. The joists 24 support an outer or veranda roof, not shown. In other embodiments, the joists 24 are supported by the upper inner square frame and a multipart connector 9. The edge beam 10 of the multipart connector 9 can support a gutter facia beam. The distal end of the edge beam 10 can be supported by an additional support post if necessary, or as shown in FIG. 9, the joist are mounted between the upper inner and outer square frames.

The roof structure 22 is supported by the upper inner square frame 15 and upper outer square frame 14. Roof tiles, tin sheets or other preferred material can be used to cover the roof structure 22. A gutter 35 is attached around the perimeter of the roof concentrically outside the upper inner square frame where only the upper inner square frame supports the roof joists (not shown in the FIGS.).

FIG. 10 is it a top view of the construction 1 in the form of a dwelling. This FIG. is looking through the roof structure 22. One living area or room 25 is shown in this FIG. and it will be appreciated other rooms can likewise be defined. The room include a floor 26 disposed over the inner square frame 7 and a decking 27 disposed over the outer square frame 2 intermediate the inner square frame 7 and the edge of the outer square frame 2. A roof 22 is shown extending over half of the construction 1.

t The floor 26 shows a plurality of planar floor panels 36 providing an inner support surface. A plurality of standard C-section beams are use to support the floor panels 36. FIGS. 11 to 20 show various views of different wall, door and window panels 28.

The panels 28 are configured to be removably mounted between the floor 26 and the 00 5 upper inner square frame 15. In this way, any preferred combination of wall structure, including doors and windows, can be disposed in and around the construction 1. The oo00 panels 28 are removable so that they can be re-configured as desired. The wall panels 28 inside the inner square frames (shown best in FIG. 10) are formed from two panels each having a width being about half the standard length and a height of about a 10 standard length.

The panels inside are removably connected at one end to each other and at the other to the upper and lower inner square frames such that the panels are substantially at right angles to each other. This provides a self bracing structure that can be easily rearranged or be modified by the use of other panels 28.

The panels 28 are equal in height to about the standard length and are of a width to allow a multiple number of the panels 28 to be disposed entirely along any one internal wall, two shown in FIG. 10. FIGS. 15 and 16, for example, show window surround panels. More than one panel 28 and be mounted to the frames 7 and 15 to piovide a single panel of standard length and predetermined width. It is noted that the panels 28 can be removably attached to an outer square frame side and an upper outer square frame side. In this way, the entire construction can be enclosed by any combination of panels 28 that is preferred.

FIGS. 21 and 22 are plan views of different arrangements of the construction 1 to form larger constructions 30. In this way, a construction 1 is joined to one or more other constructions 1 to form a larger construction. This is achieved by connecting the outer square frames 2 and 14 together in a side-by-side arrangement such that the outer square frames 2 and 14 are connected together at at least one corner point and at one midpoint 5 of an outer square frame 2 and 14. In this way, foundation posts 3 are shared between adjacent constructions 1.

V Once connected, internal and external areas of the constructions 1 can be defined by

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O the use of the panels 28. FIG. 22 shows a walkway 32 formed from standard lengths connecting different constructions 1 to provide a preferred floor plan.

The steps required to accurately erect the construction 1 are less than are required with the conventional post and beam method. Further, surveyors and other highly 00 skilled labour is not required as the inner frame 7 when mounted to the multipart Sconnector edge beam automatically provides alignment for the foundation posts 3.

S 10 A temporary foundation post 12 footing (see FIG. 6) is excavated and levelled. The Stemporary foundation post 12 extends a predetermined height above the ground 33 together with a corner of the inner square frame 7. The corners of the inner square frame 7 are mounted to the attachment cleat 18, one inner square frame side to each face of the cleat 18. As shown best in FIG. 4, bracket elements 19 are used to achieve this connection. This is repeated for the other corners of the inner square frame 7 such that the edge beams and the corners are level with each other.

The foundation posts 3 are then disposed at the midpoints 5 of the outer square frame and are connected to the edge beam 10 of the multipart connector 9. The footings for these posts are then provided. The upper outer square frame can be hoisted to connect to the foundation posts which will automatically jig or align the frames square. The upper inner square frame is then connected to the foundation posts by means of a multipart connector disposed intermediate.

The foregoing describes only two embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention. For example, the upper outer an inner square frames can be used to support an upper floor or floors in the same arrangement. In these cases, the cleats 18 extending from the multipart connectors connecting the upper inner square frame can also be used to provide hand rail foundations for a roof walkway or upper floor. Different standard length means and foundation posts can be used depending on local standards and availability.

tt The construction 1 can be used in urban or remote areas for any desired purpose.

SSince only a small number of different components are required, and that they can be Spartially assembled off site, for example, the inner and outer square frames, and transported en mass, they can be quickly and easily assembled. In the case of multiple 00 5 story constructions, a crane or hoist can be used to position the pre-assembled frames.

This can be useful in rapidly pre-fabricating and partially assembling the construction 00 components. This also extends to the rapid transporting and erecting and construction of the, for example, field hospitals, military posts, shelters or emergency medium to Slong term accommodation.

(-i .n SThe construction 1 can be fully enclosed with panels 28 disposed around the outer construction perimeter between the outer square frames. A balcony can also be added by means of a multipart connector edge beam 10 to support the balcony floor between foundation posts with the stabiliser braces 11 used to stabilise the edge beam

Claims (5)

1. A construction including: (-i a substantially horizontal outer square frame spaced apart from or contiguous with the ground by a foundation post disposed at the midpoint of each outer frame 0 side and at each outer frame corner wherein the foundation post extends a predetermined distance above the outer square frame, each outer frame side formed 00 from at least two primary external beams each of a standard length; an inner square frame disposed within the outer square frame and in the plane Othereof, each inner square frame side formed from a primary internal beam of the in standard length wherein each corner of the inner square frame is connected to a 0 midpoint of the outer square frame sides; a multipart connector configured to connect each primary external beam together to form an outer square frame side, the connector including an edge beam extending between the inner and outer square frames to provide a connection therebetween; and a pair of stabiliser braces moveable between a first position wherein the braces are mounted to a temporary foundation post and extend downwardly therefrom to temporarily support the temporary foundation post at each corner of the inner square frame and the edge beam level, and a second position wherein the braces are mounted between the foundation post and the end of the multipart connector edge beam at or adjacent the connection with a corner of the inner square frame.

2. A construction according to claim 1 including two or more outer square frames disposed in a side-by-side arrangement such that the outer square frames are connected together at at least one corner point and one midpoint of an outer frame side.

3. A construction according to claim 2 wherein the primary external beams and primary internal beams are formed from steel C-shaped cross-section and the foundation posts from steel square cross-section lengths.

4. A construction according to any one or claims 1 to 3 wherein an end of each foundation post extends a predetermined height above the outer and inner square frames and support an upper outer square frame substantially parallel with the lower outer square frame, and wherein the foundation posts extend from the mid-points of

13- t' the outer square frame and support the corners of an upper inner square frame with a multipart connector and the stabiliser braces disposed intermediate. A construction according to claim 4 wherein the upper inner square frame supports a roof structure disposed thereover or an upper storey floor. 00 6. A construction according to claim 4 or 5 wherein the lower inner square frame is configured to support a floor and the upper square frame configured to support a 00 roof structure. 7. A construction according to claim 4 or 5 wherein the upper and lower inner frames define a wall space therebetween wherein the frames are configured to t detachably retain a plurality of planar wall, door and/or window in-fill panels around Sthe inner frames, and wherein the upper and lower outer frames define a wall space therebetween wherein the frames are configured to detachably retain a plurality of planar wall, door and/or window in-fill panels around the outer frames. 8. A construction according to any one or claims 1 to 4 wherein the foundation posts, primary external beams and primary internal beams are formed from steel hollow square cross-section tubing of the same dimensions. 9. A construction according to any one or claims 1 to 8 wherein the multipart connector edge beam includes a cleat disposed adjacent the inner square frame, the cleat configured for securing the corners of the inner square frame thereto. A kit for use as a construction according to any one claims 1 to 9, the kit including: an outer square frames wherein each outer frame side is formed from at least two primary external beams each of a standard length; a plurality of foundation posts each of the standard length configured to support the outer square frame above the ground or contiguous therewith; an inner square frames wherein each inner square frame side is formed from a primary internal beam of the standard length, and where each corner of the inner square frame is configured for connection to a midpoint of the outer square frame sides; a plurality of multipart connectors configured to connect each primary external beam together to form an outer square frame side, the connector including an edge beam configured to extend between the inner and outer square frames to provide a connection therebetween; and -14- t a pair of stabiliser braces for each multipart connector, the stabilisers configured for movement between a first position wherein the braces are mountable to Sa temporary foundation post and extend downwardly therefrom to temporarily support the temporary foundation post at each corner of the inner square frame and the edge 00 beam level, and a second position wherein the braces are configured for mounting between the foundation post and the end of the multipart connector edge beam at or 00 adjacent the connection with a comer of the inner square frame. 11. A construction being substantially as herein described with reference to the accompanying drawings. t 12. A kit for use as a construction, the kit being substantially as herein described C)with reference to the accompanying drawings. (-i Dated this 8th day of April, 2005. Ashley Paul TALBOT By FRASER OLD SOHN Patent Attorneys for the Applicants