AU2010100356A4

AU2010100356A4 - A modular building

Info

Publication number: AU2010100356A4
Application number: AU2010100356A
Authority: AU
Inventors: Francesco Antonio Martino
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-04-16
Filing date: 2010-04-16
Publication date: 2010-05-20
Anticipated expiration: 2018-04-16

Description

I A modular building FIELD OF THE INVENTION The present invention relates to a modular building or dwelling for particular use in remote environments, such as those used to accommodate indigenous communities. In particular, the invention 5 relates to an easy-build dwelling of extruded metal and panel construction which is easy to erect onsite and provides occupants with protection from the elements, as well as the structural integrity required to withstand accidental and/or intentional damage to the building. BACKGROUND OF THE INVENTION Indigenous Australians make up some 2.4% of the population of whom around a quarter live in 10 remote and very remote parts of Australia. The poor state of indigenous housing is generally acknowledged as one of Australia's most intractable housing problems. It has been stated that the major cause of 'house failure' in these communities is not only lack of routine maintenance, but also faulty or inadequate construction and design. This has led to many houses in remote communities being abandoned by indigenous communities due to their bad state of disrepair and general risk to health and safety. 15 There is also a general need to provide improved housing, not only to indigenous communities, but for any remote area which requires fixed dwellings to be assembled quickly and easily without excessive labour requirements, and which are more structurally robust than hitherto known buildings of this type and capable of withstanding the forces of nature. There is a general desire to provide building structures that may be deployed to provide humans 20 with shelter and to overcome or at least ameliorate some of the aforementioned issues. SUMMARY OF THE INVENTION Therefore in one form of the invention there is proposed a modular building including: a base structure; a plurality of wall columns upstanding from said base structure, including axially aligned and opposed 25 wall column pairs adapted to support a roof purlin therebetween; and whereby each column of each wall column pair includes a first channel for receiving one end of said roof purlin. A building including these features is cheaply and easily erectable without the need for skilled labour, and is this optimal for use in rural environments and in particular for housing indigenous 30 communities.

2 Preferably said first channel extends the length of the upstanding column and is thus also configured to receive an internal or external wall panel. In preference each upstanding column includes at least one further channel which is perpendicularly disposed from said first channel, said at least one further channel adapted to receive an 5 external wall panel. Preferably said building is rectangular and includes a longitudinal axis, and first, second, third and fourth equally spaced apart and longitudinally aligned wall column pairs. In preference the first and fourth outer column pairs are of the same height and each accommodate a single roof purlin therebetween, the second inner column pair being of a greater height 10 than the first column pair such that a roof purlin extending therebetween is disposed higher than the first column pair roof purlin, and the third inner column pair being of still greater height for accommodating two vertically disposed roof purlins. Advantageously, the roof purlins are C-purlins of the same width as said vertical column channels. 15 Preferably a first row of sloping roof panels is fixed above the first and second column pair roof purlins and above the upper purlin associated with the third column pair. In preference a second row of sloping roof panels is fixed above the fourth column pair roof purlin and in between the vertically disposed roof purlins associated with the third column pair. In preference said base structure includes a frame having at least two load supporting elongate 20 members and a plurality of cross members extending laterally there between, said base structure including anchor members at corners of the building as well as along walls thereof to which said upstanding wall columns are attached. Alternatively said base structure is in the form of a concrete footing including said anchor members bolted thereto. 25 In a further form of the invention there is proposed a camp including a plurality of modular buildings as described above. BRIEF DESCRIPTION OF THE DRAWINGS 3 The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings; 5 Figure I illustrates a perspective view of a lateral cross members forming part of a single base frame of the building of the present invention; Figure 2 illustrates a perspective view of a single base frame; Figure 3 illustrates a 2x3 array of base frames forming the complete base frame of the building of the invention including in exploded view a plurality of stakes used to fix each corner of 10 the frames to the ground; Figure 4 illustrates a fixed complete base frame of the building of the present invention, including anchor points at appropriate positions around the frame perimeter to which wall panel support columns are attached at their lower ends; Figure 5 illustrates a plan view of the building according to a preferred embodiment of the present 15 invention; Figure 6 illustrates the fixed complete base frame of Figure 4 including wall panel support columns attached to the anchor points, wall panel U-supports, and a roof C-purlins extending between aligned wall panel support column pairs; Figures 7a-7b illustrate top and perspective views of the connection between a wall panel support 20 column adapted for use along a side of the building and the corresponding anchor point; Figures 8a-8b illustrate top and perspective views of the connection between a wall panel support column adapted for use at a cower of the building and the corresponding anchor point; Figure 9a illustrates a perspective view of a top end of a support column in accordance with a second embodiment of the invention, adapted for use along a side of the building to 25 support two external wall panels at 180 degrees, and one intermediate internal wall panel extending perpendicularly thereto; Figure 9b illustrates a ftont perspective view of a top end of a support column in accordance with a second embodiment of the invention, adapted for use at a corer of the building to support two external wall panels only at 90 degrees; 4 Figure 9c illustrates a rear perspective view of a top end of the support column and wall panels of Figure 13b; and Figure 10 illustrates the partially assembled building of Figure 6, including floor panels laid across the top of each of the floor frames; 5 Figure 11 illustrates the partially assembled building of Figure 10, including internal and external wall panels and roof panels in place; Figure 12 illustrates an enlarged cross sectional view of the roof C-purlin/roof panel arrangement at the third column pair; and Figure 13 illustrates a fully erected building in accordance with the present invention. 10 DESCRIPTION OF THE PREFERRED EMBODIMENTS The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following 15 description to refer to the same and like parts. The present invention relates to a building 10 adapted for particular use in remote areas to provide housing for indigenous communities, but it is to be understood that the building could equally well be used in any remote area for providing shelter to humans. Figures 1-12 illustrate progressively the various steps involved in erecting the building 10 of the present invention, and Figure 13 illustrates the 20 building 10 in its final erected form. Referring to Figure 1, there is illustrated a plurality of lateral C-section cross members 12 forming part of a base frame 14 illustrated in Figure 2. As will become apparent, the building 10 includes six base frames 14 which abut with each other in a 2x3 matrix. Each frame includes two inwardly directed and opposed C-section beams 16 which define outer longitudinal sides of the frame, with the lateral cross 25 members 12 extending between web portions of the opposed longitudinal beams 16 all the way along the frame to form a substantially rectangular structure. The beams are preferably formed by extruding steel of a thickness sufficient to support the weight of the building side walls, roofing, and various other components (not shown). Figure 3 illustrates the 2x3 array of base frames 14, including stakes or pegs 17 used to fix each 30 corner of the frames 14 to a ground surface. In the embodiment shown, each stake 17 includes a head portion and a lower threaded portion, the head portion adapted to abut with a lower horizontal flange of 5 either a longitudinal beam 16 or a cross member 12 of the base frame 14. It is to be understood however that any suitable fixing means could be used and in fact the plurality of base frames 14 could be replaced with a slab of concrete (not shown). The benefit of having the floor frame like so is that it is cheaper than laying a slab of concrete, and it elevates the building from the ground and provides a passage of air there 5 beneath. The next step in the erection process is illustrated in Figure 4 and involves fixing anchor members 18 and 20 at various locations around the perimeter of the building base frames. The anchor member 18 is designed for corners of the building, whilst anchor member 20 is designed for positioning along an external wall, the exact configuration of these members being described in more detail below. 10 Figure 5 illustrates a plan layout of the building 10 in accordance with a preferred embodiment of the invention, however, it is of course to be understood that any desired layout could be constructed using the components and method of construction of the building 10 of the present invention. In the embodiment shown, there is a bathroom 22 located at one corner including an internal access doorway 23, two external access doorways 24 on opposed longitudinal sides of the building 10 at approximately the 15 centre. There are also four windows 25, two of which are located on one longitudinal side and the other two on the opposed side. Illustrated in Figure 6 is a partially assembled building including all frame elements erected, including the base frames 14 and anchor members 18 and 20, as previously described, as well as vertical wall support column pairs 26, 28, 30 and 32, and roof C-purlins 33 extending between aligned vertical 20 wall support column pairs. Also illustrated are U-shaped frame members 34 which are supported above the base frames 14 and located according to the position of internal and external walls, the frame members 34 adapted to receive wall panels 36 (not shown in Figure 6). The configuration of the roof C purlins 30 is described in more detail below. The way in which each of the vertical wall support columns 18 and 20 is anchored to the base 25 frames 14 is shown clearly in Figures 7a-7b (for anchor members 20 and side wall column pairs 28 and 30) and Figures Sa-8b (for anchor members 18 and corner column pairs 26 and 32). Anchor member 18 is adapted for each point around the building where two walls meet at a perpendicular angle, for example, at the corners of the building, and anchor member 20 is adapted for use along side walls of the building and/or where there is an internal wall although as per the present embodiment, there can be an internal 30 wall without necessarily having an associated vertical wall support column. The anchor members 18 and 20 include mounting plates 38 upstanding from a horizontal base plate 39 adapted to be bolted down to the base frames 14. In particular, corner anchor member 18 includes two perpendicular plates, and side wall anchor member 20 includes a single upstanding plate.

6 Turning now to the configuration of the columns, the cross section of each column in column pairs 28 and 30 is substantially rectangular and includes a single, elongate back plate 40 adapted to extend on the outside of, and abut with, the single mounting plate 38 of anchor member 20. The back plate 40 turns inwardly a short distance at ends thereof, and then terminates in oppositely directed C-section 5 channels 42 for receiving external wall panels at 180 degrees from one another. The gap 44 between the two C-section channels is approximately the same as the internal width of each channel 42, which means that an internal wall can be inserted into the gap 44 and extend perpendicularly to the external panels. The back plate 40 includes a plurality of apertures which become coaxially aligned with correspondingly positioned apertures of the mounting plates 38 of anchor member 20. Any suitable fastening means such 10 as bolts 48 can then be inserted through the coaxially aligned apertures to connect the columns to the plates. The cross section of each column in column pairs 26 and 32 is substantially square and includes two perpendicular back plates 50 adapted to extend on the outside of, and abut with, the perpendicular plates 38 of the anchor member 18. Each plate 50 similarly turns inwardly a short distance, however 15 rather than terminating in opposed C-section channels, they terminate in two perpendicularly offset C section channels 52. These channels are for receiving external wall panels at 90 degrees from one another, for example, at the corners of the building. The perpendicular back plates 50 also include apertures which become coaxially aligned with apertures (not shown) of the mounting plates 38 of anchor member 18. Again, any suitable fastening means such as bolts 54 can be inserted through the coaxially aligned 20 apertures to connect the columns to the plates. Both styles of column are open hollow structures, but it is to be understood that they could be designed differently whilst still performing the same function. For example, Figures 9a-9c illustrate "side" and "corner" support columns 56 and 58 respectively which are of a closed square shaped construction having wall panel receiving C-section channels 60 extending outwardly from two or three 25 sides thereof depending on the location of the columns. These, or similarly designed columns, could also be used internally, for example, at the junction between two perpendicular walls. The next step is that floor panels 62 are to be laid, and wall panels 36 and roof panels 64 inserted in place. The floor panels 62 are to be laid above the base frames 14 and inside the U-shaped wall panel receiving members 34 located around the perimeter of the building and internally where there are internal 30 walls. The floor panels 62 may be, but do not necessarily need to be, of the same construction as the wall panels 36 described below. Figure 10 illustrates a partially erected building 10 with the floor panels 62 laid. The C-section receiving channels of each vertical column are of a size to allow for the snug fit of the wall panels 36. The panels 36 are preferably rectangular shaped composite panels comprising a fire 7 resistant core of insulation material with a metallic outer skin on either side. Such panels, particularly when supported as described, are extremely strong and dent and scratch resistant. Although not shown in detail, the outer skin has male and female elongate edges (not shown) to allow for panels to be coupled together by way of engagement between the male and female portions of two adjacent panels. Figure 11 5 illustrates the building 10 including all external wall panels erected between vertical support columns, and the internal wall panels also in place. Also shown are the roof panels 64 in place to form a sloping roof on either side of the central longitudinal axis, the roof panels 64 being of the same construction as the wall panels. It is to be understood that erection of each wall of the building 10 could be achieved in a number 10 of ways. For example, an entire wall of the building including columns, wall panels having windows and doorways cut out, etc, could be erected and then the whole wall structure lifted into place so that the vertical support columns can then be fastened to the base frames 14 as described above. In the embodiment shown, the vertical columns are each fastened to the base frames 14 through the anchor members first, and then the wall panels, etc, simply inserted in place. 15 Turning now to the configuration of the roof, each C-purlin 33 is mounted such that they extend into the gap 44 between each of the corresponding vertical support column pairs 26, 28, 30 and 32. Outer column pairs 26 and 32 are approximately the same height and thus the two roof purlins associated with these vertical column pairs extend at approximately the same height above the ground. The first inner column pair 28 is taller than the adjacent outer column pair 26 by approximately a width of a C-purlin 33 20 such that the C-purlin associated with that column pair extends slightly higher than the outer C-purlin. The second inner column pair 30 adjacent outer column pair 32 is still taller, in that it must accommodate not only two oppositely directed C-purlins 33 one above the other, but also a roof panel 62 wedged therebetween, as shown clearly in Figure 12. This roof beam/panel configuration is important in that it allows the roof structure to be quickly 25 and easily erected, whilst still maintaining structural integrity and providing a sloping surface to direct rain off the roof. Obviously, one would commence on the vertical column pair 32 side, and once the purlins 33 are in place (just the lower purlin of column pair 30), the roof panels can be laid thereabove and connected to the upper flange portions of each C-purlin using screws, bolts or rivet connections, or any other suitable fixing means. Once the panels on that side are laid, then the upper of the two C-purlins 30 extending between column pair 30 can be put in place, as well as the C-purlins extending between column pairs 26 and 28, and roof panelling then fixed thereabove in the same way as described earlier. Although not shown, it is envisaged that cladding material will be used to cover the gaps at the ends of the roof, as well as any other gaps present, however this is not essential for basic housing.

8 Figure 13 illustrates the completed modular building 10 of the present invention, including doors and windows installed. The skilled addressee would realise the ease at which this permanent structure which is capable of providing shelter to human occupants and having a structural integrity to be long lasting and withstand intentional and/or deliberate damage, can be manufactured and erected. All of the 5 frame components are extruded pieces of metal which are adapted to be transported to a site in modular form and then assembled by unskilled workers. This is particularly advantageous in indigenous communities where any member of the community may become actively involved in erecting such buildings and establishing improved housing for their community. Further advantages and improvements may very well be made to the present invention without 10 deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. In any claims that follow and in the summary of the invention, except where the context 15 requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further features in various embodiments of the invention.

Claims

1. A modular building including: a base structure; a plurality of wall columns upstanding from said base structure, including axially aligned and 5 opposed wall column pairs adapted to support a roof purlin therebetween; and whereby each column of each wall column pair includes a first channel for receiving one end of said roof purlin.

2. A modular building according to claim I wherein said first channel extends the length of the upstanding column and is thus also configured to receive an internal or external wall panel. 10

3. A modular building according to claim I or claim 2 wherein each upstanding column includes at least one further channel which is perpendicularly disposed from said first channel, said at least one further channel adapted to receive an external wall panel.

4. A modular building according to any one of the above claims wherein said building is rectangular and includes a longitudinal axis, and first, second, third and fourth equally spaced apart and 15 longitudinally aligned wall column pairs, whereby the first and fourth outer column pairs are of the same height and each accommodate a single roof purlin therebetween, the second inner column pair being of a greater height than the first column pair such that a roof purlin extending therebetween is disposed higher than the first column pair roof purlin, and the third inner column pair being of still greater height for accommodating two vertically disposed roof purlins; and 20 whereby a first row of sloping roof panels is fixed above the first and second column pair roof purlins and above the upper purlin associated with the third column pair, and a second row of sloping roof panels is fixed above the fourth column pair roof purlin and in between the vertically disposed roof purlins associated with the third column pair.

5. A modular building according to any one of the above claims wherein said base structure includes 25 a frame having at least two load supporting elongate members and a plurality of cross members extending laterally there between, said base structure including anchor members at corners of the building as well as along walls thereof to which said upstanding wall columns are attached.