AU2013201744A1

AU2013201744A1 - Transportable steel structure enclosed unit module and its manufacturing method

Info

Publication number: AU2013201744A1
Application number: AU2013201744A
Authority: AU
Inventors: Jianzhong Zhang
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-05-07
Filing date: 2013-03-21
Publication date: 2013-11-21
Also published as: CN102644392A

Abstract

Abstract This invention relates to a transportable steel structure enclosed unit module. Its properties lie in the following: the materials include shape steel framework, and the concrete cladding or cladding of fiber cement board, wood board, magnesium board, aluminum panel and steel rib on top of the shape steel framework. Not only the unit modules of this invention can be converted into other functions but also can be flexibly made into various designs and adjustments. Unit modules can be produced in batches through stereotyped manufacturing in production lines, which are suitable for transportation requirements. Besides, this invention makes a manufacturing method of unit module known to the public.

Description

- 1 TRANSPORTABLE STEEL STRUCTURE ENCLOSED UNIT MODULE AND ITS MANUFACTURING METHOD Technical field [0001] This invention relates to a steel structure enclosed unit module, and specifically relates to a transportable steel structure enclosed unit module. Background arts [0002] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field. [0003] In logistics field, the most frequently used vessels are containers, which are normally of the structure having steel framework and with iron sheet or fiberboard attached thereto. It must be of light weight and high structural strength so its weight can be reduced to the minimum and more cargos can be contained in fixed space. For sea shipping containers, higher requirements on weight and capacity are needed, and in meanwhile other characteristics, such as corrosion free shall be of consideration. [0004] In specific fields, such as inland coal mine and oil exploration, equipment delivery has always been a headache for the developer or the contractor. Specifically, in such cases, it is sometimes requires that the equipments gone through long-distance shipping and then long -distance highway transport before they arrive on site. After unloading the equipments, the costs for shipping those empty containers back are also high, e.g., the cost of transporting the containers back even to the nearest port delivery may has exceeded the cost of the containers -2 themselves. Thus, the developer or the contractor has to find solution to dispose those containers at their lowest costs. [0005] In such exploiting field, on the other hand, houses should be provided on site generally. Usually prefab houses or temporary houses are constructed and normally they are made of color steel with poor soundness and heat retaining properties. Moreover, it leads to extra cost to build. [0006] Also, various technologies of shape steel combined with concrete are currently available. Workers will build steel cage and pour concrete on site which means they are only applicable on site and is not applicable to repeated production. [0007] Therefore, there is a need in the art to provide a transportable steel structure enclosed unit modules and they can be converted into houses directly after arrival. Summary of invention [0008] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. [0009] One purpose of this invention is to provide a steel structure enclosed unit module that is transportable, and/or convertible into houses directly with good soundness and heat retaining properties. [0010] One aspect of the present invention provides a transportable steel structure enclosed unit module comprising a shape steel framework, and cladding attached to the respective side of the shape steel framework wherein the cladding is at least one of concrete, fiber cement board, wood board, magnesium board, aluminum panel as well as steel ribs.

-3 [0011] In a preferred embodiment, the shape steel framework is basically of straight-Hexahedron with the following structural properties, I e, solid steel for four pillars, truss structure for beams. The adoption of this structure can lessen the whole weight while guarantee the structural strength.In another preferred embodiment, the cladding is concrete claddings are made of light aggregate concrete, which can reduce the weight of concrete claddings, meanwhile keep the flexibility and its structural strength. [0012] Preferably, door and window openings are provided on the concrete claddings which are for e.g. fixing plastic steel door and window on the door and window openings. [0013] Preferably, holes for hoist are provided on the four pillars of the shape steel framework. With setting up such holes for hoist, integral hoisting for the unit can be reached. Thus force can be applied utmost evenly onto the unit during transportation and the structural strength is maintained, such that cracking of the concrete claddings due to uneven force can be avoided. [0014] Preferably, at least one reinforcing pillar is provided on the shape steel framework, at least one C-shaped steels or lightgage steel joists are fixed on the at least one reinforcing prop for attaching inner-surface plate. [0015] Preferably the inner-surface plate is magnesium board. This structure can provide smooth inner surface so that the unit modules can be quickly converted into accommodations with low cost after they are delivered to the site. [0016] Preferably, this unit module has followed the standardized dimension of container sizes. For example, the unit module appearance has adopted the shaped dimension in line with the international convention, which includes several types below: nominal 12192* 2438* -4 [0017] 2896 (Length * Width * Height, dimensions in millimeters); nominal 6058* 2438* 2896 (Length * Width * Height, dimensions in millimeters). [0018] Preferably, standardized container feet are placed in respective corner of the unit module in accordance with container manufacturing requirements. [0019] Preferably, the claddings is constructed as, using fiber cement board that fixed on C-shaped steel or lightgage steel joist as supporting walls, and have PU, i.e. polyurethane, filled in the middle of the walls. [0020] another aspect of this invention directs to a manufacturing method of transportable steel structure enclosed unit modules with polyurethanes filled-in claddings which comprises following steps fixedly connecting the steel beams and steel pillars to form a steel framework; fixedly connecting C-shaped steel or lightgage steel joist pillar to the steel framework; fixedly connecting fiber cement board, wood board, magnesium board, aluminum panel, steel rib claddings onto the C-shaped steel or lightgage steel joist pillar on one side of this steel structure so that it can enclose at least one side of the steel structure to form an enclosed structure. Then laying water and electrical pipelines within the enclosed structure; fixedly connecting fiber cement board, wood board, magnesium board, aluminum panels, steel rib claddings on the offside C-shaped steel or lightgage steel joist pillar of the ready-to-close enclosed structure to form a half-enclosed cavity; reinforcing and clamping this enclosed cavity internally and externally; filling PU foam into the half-enclosed cavity; A and removing the clamps after the PU foam solidifies so that the manufacture of a unit module on the side wall is completed, Repeating the steps of forming side wall unit modules on the side wall. [0021] After we finish the above steps, install concrete claddings or surfaces made of other materials on the top and bottom of the steel structure to add top and bottom surfaces for the unit module.

-5 [0022] Not only are the unit modules of this invention are multi-functional but also the structure is flexible, they can be used in every design and adjustment. The unit modules can be customized in batches in the factory. They are suitable in production line for manufacture and also fit for transportation requirement. Description of Drawings [0023] One or more preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: [0024] Figure 1 is an elevation view of the shape steel framework for transportable steel structure enclosed unit module according to one embodiment of this invention; [0025] Figure 2 is an elevation view of the shape steel framework for transportable steel structure enclosed unit module according to another embodiment of the invention; [0026] Figure 3 is a perspective view a perspective view of the pillar in Figure 1; [0027] Figure 4 is a perspective view of rear upper beam in Figure 1;; [0028] Figure 5 is a perspective view of rear lower beam in Figure 1; [0029] Figure 6 is a perspective view of front top beam in Figure 1; [0030] Figure 7 is a perspective view of front lower beam in Figure 1; [0031] Figure 8 is a perspective view of side beam in Figure 1; [0032] Figure 9 is a perspective view of the reinforced beam in Figure 1; -6 [0033] Figure 10 is a perspective view of the middle beam in Figure 1; [0034] Figure 11 is a perspective view of middle pillar in Figure 1; [0035] Figure 12 is the structural section view of the concrete cladding; [0036] Figure 13 is the structural perspective view of the concrete cladding; [0037] Figure 14 is the structural section view of the other claddings of this invention; [0038] Figure 15 is enlarged view of another cladding Description of the Preferred embodiments [0039] Detailed embodiments of the invention will be described below with reference to the drawings accompanied. It should be understood that the explanation should be demonstrative rather than restrictive. [0040] Referring now to Figure 1, transportable steel structure enclosed unit module 100 according to one embodiment of the invention comprises a framework substantially in of the shape of straight hexahedron and concrete claddings attached on respective side of the frame. The concrete claddings include concrete walls, concrete ceiling as well as concrete floor. [0041] The Straight hexahedron framework includes pillars 10, rear upper beam 20, rear lower beam 30, front upper beam 40, front lower beam 50, and side beam 60 and reinforced beam 70 all of which are rigidly or fixedly connected to each other to form the framework. Among them, the four pillars 10, together with rear upper beam 20, rear lower beam 30, front upper beam 40, front lower beam 50, side beam 60, form the straight hexahedron framework. The reinforced beam 70, -7 which is fixed between side beam 60 and pillar 10, is to increase the rigidity of the framework. The rigid connection can be realized by welding, bolt fastening and riveting etc. [0042] As shown in the perspective view figure 3, the pillar 10 can be square steel, which has shown that holes for hoist can be made in both ends of square steel. [0043] It is shown in Figure 4 that the structure of rear upper beam 20 can be truss construction. It can be two U Steels opposing to each other, with fixed steel ribs on both sides. The steel ribs can be arranged incline or vertical to the beam and can be arrange in intervals. [0044] An example of the rear lower beam 30 is shown in Figure 5. According to figure 5 the beam 5 is in a truss structure, which can be formed by attaching steel ribs which are parallel to each other to both sides of a U Steel. [0045] The structure of the front upper beam 40 is shown in Figure 6 which can be square steel. [0046] The structure of front lower beam 50 is shown in Figure 7, which is similar to rear lower beam. i.e., it can be a truss structure which can be formed by attaching steel ribs which are parallel to each other to both sides of a U Steel. [0047] The structure of side beam 60 is shown in Figure 8, which can be a truss structure which can be formed by attaching steel ribs on both sides of two U Steel arranged opposing to each other,. The steel ribs can be arranged incline or vertical to the beam and can be arrange in intervals. [0048] The structure of reinforced beam 70 is shown in Figure 9, which can be the structure of a U Steel with holes.

-8 [0049] A plurality number of reinforced pillars 80 are provided on the shape steel framework although only two are shown in Figure 2, many C-shaped steels or lightgage steel joists 81 are fixed on this reinforced pillar, the inner surface board 90 and the outer surface board 91 are fixed on respective side of the C-shaped steels or lightgage steel joists. The purpose of providing reinforced pillar 80 is to facilitate the movements of the boards when fixing the module. Meanwhile, these reinforced pillars form a unity with the entire steel structure, undertaking and resisting the deformation likely to occur during hoisting and transportation. [0050] The upper and the lower middle beams 61, 62 are arranged between the side beams, the middle beams can connect the middle pillar 11, as shown in Figure 10, 11, so as to form the support of the middle part of the framework. The structure, which is enclosed with top and lower middle beam 61, 62 as well as middle pillar 11, can set a cladding with or without openings, so as to divide the unit module into separated rooms. The middle pillar has the same structure with the reinforced pillar 80, while the middle beams 61, 62 have the same structure with side beam 60. [0051] One example of the structure of the concrete cladding is shown in Figure 12 and 13, which includes a reinforced layer a steel wire mesh which is set up on the outer side of the reinforced layer and the concrete which is poured onto the reinforced layer and the steel wire mesh so as to fill- the gaps between the reinforced layer and steel wire mesh. The concrete claddings can be turned into concrete side wall on the side of the shape steel framework. The concrete claddings formed on the top and bottom of shape steel framework are Concrete ceiling and concrete floor respectively. [0052] Concrete cladding which is made of light aggregate concrete can be used. The adoption of light aggregate concrete can reduce the weight of precast concrete slab and meanwhile keep its flexibility and structural strength.

-9 [0053] A plurality number of C-shaped steels or lightgage steel joists are used to fix the inner surface panels on the inner sides of the concrete side wall, the inner surface panels can be magnesium board or other complex structures. [0054] The inner or outer surface panels are optional items. Depending on the necessity of surface finish, the workers can directly work on the concrete surface for surface decorations. In The above mentioned embodiments surface panels are used to substitute the function of the module. Meanwhile, its property of smooth surface lessens the workload of decoration. [0055] In another embodiment, the structure of cladding is shown in Figure 14 and 15, which is formed by first using fiber cement board which is fixed on C shaped steels or lightgage steel joists instead of concrete cladding as enclosed walls, and then filled-in the space between the side walls with PU, i.e. polyurethane. An implementation of such structure can be as follows: after finishing the structure, a side board is enclose, the board is typically high density fiber cement board (can be chosen from wood board, magnesium board, aluminum panel or steel rib), fixing the board on to the attached C-shaped steel (or lightgage steel joist skeleton); and then laying water and electrical pipelines inside the structure that is ready to be enclose; sealing the board with the same quality as above on the other side to form a semi-enclosed cavity; clamping the inside and outside of the enclosed cavity so that they are reinforced filling PU foam into the formed semi-enclosed cavity; waiting for solidification of the foam, removing the clamping, then completes the manufacture of a side wall unit module. Repeat the same steps of forming side wall unit module, then we can make other side walls; then install concrete claddings on top and bottom of the steel structure, thus we finish the manufacture of the unit module. [0056] Figure 2 has shown another embodiment of this invention, in which a middle pillar between the front upper beam and front lower beam is provided, and a - 10 middle beam between front lower beam and rear lower beam of the straight hexahedron framework is provided. [0057] Other structures are identical with the ones in the first embodiment. [0058] The transportable steel structure enclosed unit module of this invention is engraved with "customized", which means we can open holes, install doors and windows on the concrete side wall according to our customers' request. We can design its strength based on customer's need and install reinforced beam. The inner surface can be decorated depending on its implementation. [0059] Steel reinforced concrete has good properties of fire resistance and water resistance, which is suitable for shipping. By optimizing its structure, we can make the best use of the materials' complex properties to lower the steel volume. [0060] Our comprehensive cost control of the whole transportation enables us to turn the container into useable housing or office by the analysis of the use requirement, purpose of purchase and cost of transportation at the destination. After they have undertaken their function as unit modules, they will continue to work for the next step of the cargo destination, so the whole purchase cost can be lowered. [0061] Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to". [0062] Although the invention has been described with reference to specific examples it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

1. A transportable steel structure enclosed unit module, comprising a shape steel framework, and cladding attached to the respective side of the shape steel framework wherein the cladding is at least one of concrete, fiber cement board, wood board, magnesium board, aluminum panel as well as steel panel.

2. The module as claimed in Claim 1, wherein the shape steel framework is basically of straight-Hexahedron with the following structural properties, I e, solid steel for four pillars, truss structure for beams. The adoption of this structure can lessen the whole weight while guarantee the structural strength.

3. The module as claimed in Claim 1, wherein the concrete cladding is made of light aggregate concrete.

4. The module as claimed in Claim 1, wherein door and window openings are provided on the concrete claddings which are for e.g. fixing plastic steel door and window on the door and window openings.

5. The module as claimed in Claim 1, wherein, holes for hoist are provided on each of the four pillars of shape steel framework.

6. The module as claimed in Claim 1, wherein. at least one reinforcing pillar is provided on the shape steel framework, at least one C-shaped steels or lightgage steel joists are fixed on the at least one reinforcing prop for attaching inner-surface plate. Preferably the inner-surface plate is magnesium board.

7. The module as claimed in Claim 1, wherein the inner surface board is magnesium board, cement board, shaped aluminum panel, or wood board. - 12

8. The module as claimed in Claim 1, wherein polyurethane is filled-in the space between the inner and outer surfaces of the fiber cement board claddings.

9. The module as claimed in Claim 1, wherein the appearance of this unit module adopts the shaped dimension in line with International Container Convention, preferable width is within 4200 mm, preferable length within 15000 mm and preferable height within 3500mm.

10. A method of manufacturing a transportable steel structure enclosed unit module with polyurethane filled-in claddings, comprising the following steps: fixedly connecting the steel beams and steel pillars to form a steel framework; fixedly connecting C-shaped steel or lightgage steel joist pillar to the steel framework; fixedly connecting fiber cement board, wood board, magnesium board, aluminum panel, steel rib claddings onto the C-shaped steel or lightgage steel joist pillar on one side of this steel structure so that it can enclose at least one side of the steel structure to form an enclosed structure; laying water and electrical pipelines within the enclosed structure; fixedly connecting fiber cement board, wood board, magnesium board, aluminum panels, steel rib claddings on the offside C-shaped steel or lightgage steel joist pillar of the ready-to-close enclosed structure to form a half-enclosed cavity; reinforcing this enclosed cavity internally and externally by clamp; filling PU foam into the half-enclosed cavity; and removing the clamps after the solidification of the PU foam so that the manufacture of a unit module on the side wall is completed; and repeating the steps of forming side wall unit modules on the side wall. - 13

11. A transportable steel structure enclosed unit module substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples.

12. A method of manufacturing a transportable steel structure substantially as herein described with reference to any one of the embodiments of the invention illustrated in the accompanying drawings and/or examples.