AU2015215828B2 - Transporting of structural elements - Google Patents

Abstract

A module for storing and/or transporting prefabricated building panels, such as internal and external wall panels, includes a horizontal base assembly and a vertical support 5 structure to support the panels in a vertical orientation using a securing arrangement in the form of straps to secure the panels to the vertical support in stacked side-by-side vertical relationship. The module can be in the form of stillage or permanently mounted to the load carrying part of a suitable motor vehicle, such as a flat bed or tray truck. The module can be loaded with panels and stored at the production site io awaiting transportation to a building site or can be off loaded at the building site as a unit for storing the panels until needed for use. Using the module improves efficiencies to lower construction costs relating to storing, handling, transporting and installing the panels. 6785680 1 (GHMalers) P97671.AU.1 JMC 0< C)C ff/MC7 ill CIO IIBM€B Mtj isecoi nR! <

Description

TRANSPORTING OF STRUCTURAL ELEMENTS

TECHNICAL FIELD

Disclosed is an apparatus, method and system for retaining structural elements, particularly when storing and/or transporting the structural elements prior to their use.

In one form, the disclosure relates to structural elements in the form of prefabricated walls, panels and sheets for use in construction and building applications in the io construction and building industries, including their use in construction building structures.

The present disclosure particularly relates to the use of an apparatus in the form of a module for securely storing and/or transporting structural building components between different locations, such as from a manufacturing facility to a use location, such as a building site.

It should also be understood that protection for the apparatus, particularly in the form of a module, method and system disclosed herein is not limited to the transportation of 2 0 prefabricated walls, panels and sheets only, but rather the scope of protection is more extensive to include storing and transporting other structural elements, and the use of other forms and variations of the module than specifically described.

BACKGROUND ART

Structural elements such as prefabricated walls, panels and sheets for use in construction and building applications, including constructing building structures at a building site, are, for safety reasons and ease of handling, often transported in an orientation corresponding to the elements lying flat on a supporting surface, such as for 30 example, on the flat bed/tray of a truck or similar commercial vehicle. This configuration reduces the number of individual panels or sheets that can be stacked one above the other owing to the weight of the stack on the lowermost panel which can damage the panel by crushing or cracking the panel.

Glass panels and sheets are generally transported in a different orientation usually

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- 2 corresponding to the glass being in an upright position, such as for example, standing up but inclined at an angle to lie against a supporting A-frame or similar structure having an inclined support surface on the flat bed/tray of a truck. The use of an Aframe reduces the amount of panels that can form a single load because of the additional space required or footprint of the panel due to the inclination of the sheets which takes up more room on the truck load area than is necessary.

Thus, there is a need for an improved method and apparatus which can safely and securely store and/or transport a greater number of panels in a single load using the io same motor vehicle.

The above references to the background art do not constitute an admission that the art forms part of the common general knowledge of a person of ordinary skill in the art within Australia. The above references are also not intended to limit the application of 15 the apparatus, method and system as disclosed herein.

SUMMARY OF THE DISCLOSURE

According to one form of the present invention, there is provided a module for

0 containing at least one structural element having at least one outer surface, the module comprising a planar base assembly having a first side portion and a second side portion, the base assembly for supporting the module when located on a substrate for transportation of the module, a support assembly for supporting the at least one structural element in a desired orientation of the structural element, the support assembly connected to the base assembly to extend outwardly from the base assembly to divide the base assembly into the first side portion located on one side of the support assembly and the second side portion located on the other 30 side of the support assembly, the first side portion and the second side portion being opposite side portions of the base assembly, and a securing arrangement to secure the at least one structural element to the module, the securing arrangement including a flexible securing element having a first

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- 3 end and a second end and an actuator for operating the flexible securing element to secure the structural element to the module, the flexible securing element extending between the support assembly at or towards the first end thereof and the base assembly at or towards the second end thereof wherein when the flexible securing element extends between the support assembly and the base assembly the flexible securing element is in contact with the outer surface of the at least one structural element and passes from the first side portion of io the base assembly to the second side portion of the base assembly underneath the structural element to retain the structural element in the desired orientation against the support assembly.

According to one embodiment, the module is for transporting and/or storing at least 15 one structural element, preferably multiple structural elements, in a generally upright orientation.

In one form, the structural element can, for example, be a building component, such as, a prefabricated wall, panel or sheet. Typically, the building component includes

0 engineered housing panels for use in building or constructing a building structure, such as the wall or floor of a dwelling unit or house, although it is not so limited.

Typically, the building structure is a commercial or residential building, including a domestic dwelling or similar.

Forms of the panel can include two or more layers, typically a central core located between an outer covering on either side. Forms of the panel include layered panels, composite panels, laminated panels or the like. Typically, the panel is or contains as one or more layers, a panel made from autoclaved aerated concrete (AAC).

The transport apparatus can accommodate a multitude of planar or panel-like similar or different structural elements arranged generally to extend in an array in a substantially vertical orientation and generally in a stack of panels in side-by-side relationship to one another, preferably in abutting face-to-face relationship, so as to be able to be safely and securely transported or stored in such an orientation. By being able to safely

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- 4 transport the structural elements in a generally upright orientation in abutting face-toface relationship enables the number of structural elements that can be transported in a single load to be increased, typically to be maximised by maximising volume utilisation efficiency (MVUE) on the transport vehicle by each individual panel occupying a minimum of space due to its vertical orientation. Thus, the footprint of each panel is smaller when arranged vertically rather than inclined at an angle. In addition, the vertical, side-by-side face-to-face orientation can help to facilitate loading and unloading of each structural element as required so as to minimise cycle time in loading and unloading, thereby improving the overall efficiency of supply of the io structural elements, and hence of the construction of the building structure.

In this regard, the apparatus is a module having a support assembly which comprises a generally vertically extending upright supporting structure or support framework. The upright supporting structure or framework sometimes referred to as the upright in this 15 specification, can be arranged with respect to a loading area of a vehicle such as a flat bed or tray of a truck. For example, the upright support structure or assembly can take the form of an elongate frame made from a multitude of interconnected framework members that, in-use is substantially vertically extending, such as extending upwardly from the plane of a base assembly of the module or from the vehicle loading area.

0 When structural elements have the form of prefabricated walls, panels or sheets, the panels can be located on the load carrying portion of the transport vehicle to be arranged collectively in parallel with the vertically extending support frame. The panels can be arranged in parallel relationship to each other so that the innermost such wall, panel or sheet is supported by the frame, with the remaining walls, panels or sheets being located in substantially parallel relationship by being indirectly supported by the frame by abutting against the innermost panel.

Forms of the apparatus or module also include a securing arrangement. In one form, the securing arrangement is arranged to cooperate with the upright frame to secure the 30 at least one structural element with respect to the upright in or on the vehicle loading area. For example, when the at least one structural element has a panel-like form, the securing arrangement can cooperate with the upright such that one or more of the panel-like structural elements are each able to be secured with respect to the upright and to other parts ofthe module to extend vertically in use.

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- 5 In one form, the securing arrangement includes a securing element and an actuator in the form of a securing mechanism for actuating the securing element. In one form, the actuator is a handle or an electrical motor and the securing mechanism is a winch, either a hand operated winch or a winch driven by an electrical motor.

In one embodiment, the upright is arranged to extend centrally along the loading area of the vehicle such that at least one structural element is able to be secured on each side of the upright, preferably multiple panels on each side. For example, when the vehicle loading area is a flat bed or tray, the upright support structure, typically in the io form of a frame, can be arranged to extend along a central longitudinal axis of the flat bed or tray so that the structural elements can be secured to both sides of the upright to occupy a minimum volume or footprint.

In one embodiment, there is a single securing mechanism in the form of a winch and/or 15 a securing element for securing a multitude of structural elements collectively.

In one embodiment, there are two or more individual securing mechanisms for securing each structural element or for securing all structural elements.

0 In one form, the securing mechanism, in the form of one or more winches, are fixedly attached to the lengthwise extending sides of the frame or module, preferably in spaced apart relationship to each other.

In one form, two or more securing elements cooperate with each other to secure the 25 structural element.

In one embodiment, a securing mechanism may be provided for each structural element. For example, each such securing mechanism can cooperate with the upright to secure one respective structural element at the vehicle loading area. The provision 30 of a securing mechanism for each individual structural element allows the elements remaining on the vehicle to be held securely in place without risk of unwanted movement whilst adjacent elements are being loaded or unloaded individually.

In one embodiment, the transportation apparatus or module can comprise a base 35 assembly in the form of a base to which the upright can be mounted to extend

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- 6 upwardly, typically, orthogonally therefrom in use. Further, the base may be located on the vehicle loading area to receive the upright or frame, and then fixed into position with respect to the vehicle loading area. In one form, the base is releasably fastened to a flat bed or tray of a truck or other vehicle. In one form, the base assembly includes stabilisers. Typically, the stabilisers are outriggers, framework members, or similar elongate elements extending perpendicularly to the frame or upright. More typically, the outriggers or framework members are interconnected, preferably interconnected at their distal ends collectively.

io In one embodiment, the apparatus can take the form of stillage. In this regard, the stillage can provide a unitary transportation and/or storage unit for holding and transporting of multiple structural elements simultaneously, including structural elements in the form of prefabricated, engineered construction panels. Thus, once laden, the stillage can securely hold the one or more structural elements for storage at a suitable or desired location, such as for example, at a factory or on the building site. The stillage can also allow for improved handling and transporting of the multiple structural elements, especially when in the form of large scale panels.

Forms of the stillage can also be designed to minimise the overall height of the

0 structural units when being transported by motor vehicle to fall within roadway limitations for use on the public roads. Further, because the stillage is able to hold and store multiple loaded assemblies, typically in the form of the prefabricated panels, road vehicle demurrage can be reduced or eliminated. For example, a number of pre-loaded stillage units can be held at a fabrication facility awaiting transportation to a construction site, or having been delivered to a worksite, can be unloaded and stored at the site until needed to build the building structure, thereby freeing the load space of the vehicle for use in transporting another load without having to return to the factory or other site merely to unload the load supports, or because the truck is capable of carrying one type of load only.

In addition, because the laden stillage unit is able to be loaded from and unloaded to surrounding ground level, it can also reduce or avoid risks associated with working at height, such as the risks which can otherwise arise when securing crane linkages to loads on vehicles, or when releasing load restraints at a vehicle, particularly large size panels which are sometimes unwieldy to handle.

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- 7 In one embodiment, the securing arrangement includes a securing element, typically in the form of a strap or similar, more typically one or more straps for each structural element. For example, a shorter panel may be secured with a single strap, whereas a longer panel may require two or more individual spaced straps or two or more interconnected straps or similar.

Other forms of the securing element include a flexible member or element, including webbing, belting, strapping, tape, ribbon, rope, cord, made from natural or man-made io materials, such as nylon, polyester, polyethylene, polypropylene, aramids, Kevlar or the like, including composite or layered materials.

Another form of the securing element is nets, or octopus type straps or other networks of interconnected flexible elongate lengths of suitable materials.

In one embodiment, the, or each, strap can be arranged such that, in use, it is able to be passed over an outwardly facing surface of its respective structural element.

Further, each strap can be arranged such that a free end thereof may then be fastened at a convenient location such as at the apparatus or with respect to the vehicle, to

0 thereby secure the respective structural element with respect to the upright. Typically, the strap is passed under the panel or base assembly to be fastened on the opposite side of the module to the side having the panel.

In this embodiment, an opposite end of each strap can be secured with respect to, and 25 so as to extend from, an upper end of the upright. Thus, the straps can hang down from the upright when not in use. Typically, the straps are connected to the upright by hooks, more typically, spaced apart hooks in which each hook suspends one strap. More typically, the spacing apart of the hooks for fastening the straps corresponds to the spacing apart of the winches so that the hooks are in alignment with the winches to 30 receive the free ends of the respective straps.

In one embodiment, the base is provided with one or more apertures so that each strap can be passed through one or more of the apertures. Typically, the apertures are provided through an upper floor part of the base. Alternatively, the apertures may be 35 defined at or within the vehicle loading area. It is to be noted that the base assembly is

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- 8 provided with any part suitable for receiving and capturing the securing element, particularly in the form of strapping or straps.

In either case, the aperture can enable a given strap to be passed under its respective structural element. Having been so passed, the free end of the strap can be fastened at the base or can be fastened at the vehicle loading area. For example, the free end of the strap can be fastened at an opposite side of the upright to where the respective structural element is located.

io In one embodiment, the free end of the strap may be fed to the securing mechanism located on the base at the opposite side. Typically, the securing mechanism in the form of a winch is located at the base of the apparatus, or located at the vehicle loading area. The winch can be actuated in use to apply tension to and to maintain tension in the strap, thereby securing the respective structural element with respect to the upright. The winch can be any suitable or convenient type of winch, including hand operated winches or motor driven winches.

In one embodiment, the strap may comprise a loop, such that the free end of the strap is able to loop over the winch that is located at the base of the apparatus, or that is

0 located at the vehicle loading area.

In one form, the strap is a ratchet tie down strap made from polyester in which the free end of the strap is threaded through the ratch, rolled up and secured in the stillage during transport.

The base or base assembly of the apparatus or module can comprise lifting points for coupling to a lifting mechanism of a suitable lifting device, such as for example, to the hook of a crane, hoist or carrier for lifting the panels and/or uprights or stillage, onto or off the vehicle loading area. A series of such lifting points may be provided at convenient spaced apart locations on the base assembly. Typically, the lifting points are in the form of twist locks that are spaced out along opposing sides of the base.

Each twist lock can be releasably connected to a respective coupling that is located at an end of a respective linkage of the crane, hoist or carrier. The twist locks can also be employed to couple and secure the base to the vehicle loading area when located thereon.

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- 9 In one form, the carrier is a straddle carrier of the type which carries the load between the sides of the load area.

Also disclosed herein is a method for transporting at least one structural element on a loading area of a vehicle. The method can employ the apparatus as set forth above.

The method comprises locating and supporting the at least one structural element at the vehicle loading area such that the element extends generally vertically during io movement of the vehicle. For example, a number of structural elements can be located and supported at the vehicle loading area, in a side-by-side face-to-face relationship, and such that each extends generally vertically during movement of the vehicle.

In one embodiment of the method, each structural element may be supported in its 15 generally vertical orientation by its own securing element and/or mechanism. As set forth above, each securing mechanism may be arranged to cooperate with an upright that extends generally vertically with respect to the vehicle loading area. Further, each structural element may be located and supported with respect to the upright.

0 In one embodiment of the method, the apparatus can be located at a fabrication facility for fabricating the at least one structural element. After fabrication, each structural element can be located and supported by a respective securing mechanism with respect to the upright of the apparatus. When required, the resultant laden apparatus may then be moved by a crane or carrier to the vehicle loading or holding area, ready 25 for loading onto the vehicle to be transported to the building site.

In one embodiment of the method, having been transported to a site, the apparatus and/or the at least one structural element is/are then lifted by a crane or carrier located either on the vehicle or at the building site to be unloaded from the vehicle, such as off 30 loaded from the vehicle loading area. For example, panels can be lifted directly from the apparatus or module whilst it is on the vehicle, or the entire laden apparatus or module complete with the multitude of stacked panels, can be lifted off the vehicle as a single unit, and the panels subsequently unloaded, or just some of the panels may be pre-lifted from the apparatus, the remaining panels remaining secured in place on the 35 vehicle by their respective securing element.

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- 10 Also disclosed herein is a system for transporting to a site at least one structural element. The system comprises the apparatus as set forth above. The system also comprises a lifting device in the form of a crane, hoist or carrier to lift the apparatus and/or the at least one structural element off the vehicle loading area when located at the site. The crane or hoist can be mounted to the vehicle or separate to the vehicle and includes a mobile crane or hoist or a stationary crane or hoist.

The system may further comprise a crane, hoist or carrier located at the fabrication i o facility where the at least one structural element is fabricated. Thus, after fabrication and after each structural element has been located and supported by the securing mechanism with respect to the upright of the apparatus, the apparatus is then able to be moved, for example, lifted and carried by the crane or carrier to the vehicle loading area, ready for securement thereat and ready to be transported.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific embodiments will now be described, by way of example only, to illustrate forms ofthe invention, with reference to the accompanying drawings in which:

Figure 1A is a top plan view of one form of the support module.

Figure 1B is a side elevation view ofthe support module of Figure 1A.

Figure 1C is a side elevation view of one form of the decking of the module of Figure 1B.

Figure 1D is an end view of the form of the module of Figure 1A in a loaded configuration with a panel secured on either side.

Figure 1E is an end view similar to Figure 1D in an unloaded configuration showing one form of the securing element.

Figure 1F is a side view of one form of a top bar of the module of Figure 1B.

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- 11 Figure 1G is a side view of one form of a winch located on the side of the deck of Figure 1C.

Figure 2 is an enlarged view of Figure 1D.

Figure 3 is an end perspective view of a straddle carrier adapted for use with the module of Figures 1 and 2.

Figure 4 is a perspective view of another embodiment of the module in the form of a io stillage in an unloaded configuration.

Figure 5 is a top plan view of the embodiment of Figure 4.

Figure 6 is a side elevation view of the embodiment of Figure 4.

Figure 7 is a perspective view of the embodiment of Figure 4 in a loaded configuration.

Figure 8 is a perspective view of another embodiment of the module.

0 Figure 9 is a top plan view of the embodiment of Figure 4.

Figure 10 is a side elevation view of the embodiment of Figure 4.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Referring to Figures 1Ato 1G and 2 of the drawings, forms of an apparatus and system for transporting one or more structural elements, typically, in the form of prefabricated building panels, in a simple, expedient and secure manner is schematically depicted. Each structural element can take the form of a prefabricated, 30 engineered construction panel, generally denoted as 2, either in the form of an external wall panel 10 of relatively larger thickness, or an internal wall panel 12 of a relatively smaller thickness, as shown more particularly in Figures 1D and 2. It is to be noted that reference herein to ‘external’ and ‘internal’ wall panels is a reference to where the respective panels are to be located within a building structure, such as on the external 35 wall of a domestic house construction or as an internal wall dividing the structure into

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- 12 rooms.

The structural element can also take the form of other panel- or sheet-like engineered products for use in construction and building applications and which require transportation from a fabrication facility to a worksite, such as in the form of a wall and ceiling board, external cladding panels, framed windows, doors, glass sheets, or the like.

One form of the apparatus or module is in the form of a stillage.

io

A stillage unit, generally denoted as 20, is provided as one form of the upright support or as one form having a support assembly and a base assembly. However, it should be understood that the apparatus and system need not be embodied in a stand-alone unit, and instead can be incorporated into a transportation vehicle as a fixture fixedly 15 connected to the vehicle.

Stillage unit 20, in one form, comprises a support assembly in the form of an upright having or including an elongate frame 22 that extends vertically in use such as by extending upwardly from the vehicle loading area once stillage 20 has been located

0 thereat or thereon. Frame 22 is made from an interconnected array of framework members. Stillage unit 20 comprises a base assembly in the form of decking 24 to which frame 22 is connected to extend up from a central longitudinal axis of decking 24 which is also in the form of a framework of individual framework members.

5 Frame 22, as depicted in Figures 1A to 1G and 2 of the drawings comprises five evenly spaced upright posts 26, typically in the form of 100mm x 100mm square hollow section tubes, preferably made from steel. Posts 26 are connected to frame 20 and are connected to a framework of decking 24 to extend orthogonally therefrom.

Respective upper ends of adjacent posts 26, are connected together by respective 30 stillage top bars 28, which bars are welded at opposing ends to each post to extend collinearly to form the top member of frame 22. Each stillage top bar 28 is in the form of a length of an inverted preformed C-channel 30, having a web located between two side sections forming the walls of the C-section extending from the web. An upper connector 34 is fixedly connected to C-shaped channel 30. In one form, connector 34 35 comprises a pair of lengthwise extending flats 32 and upper elongate bar 28. One long

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- 13 edge of each flat is connected to side wall of channel 30 such as by welding forming part of elongate frame 22. Each flat 32 extends to and is connected to upper elongate bar 28 as shown more particularly in Figure 1F.

The length of each post 26 is selected such that the overall height of the stillage unit 20 falls within roadway height limitations for transport along public roads when the unit is located on a truck bed or tray.

Decking framework 24 comprises a multitude of interconnected C-channel sections 36, io typically connected together by welding to form a relatively rigid frame or grid. Deck 38 comprises a multitude of decking sections 39 which are arranged on and connected by welding or suitable fasteners to the decking framework. Decking panels 39 are spaced on the decking framework to provide strapping spaces S therebetween as shown more particularly in Figures 1B and 1C, as will be explained hereafter.

Usually stillage unit 20 is preloaded at the factory, with multiple panels 2 being located in side-by-side relationship on deck 38, on either side of frame 22 such as a single panel on either side as shown in Figure 1D. Each panel 2 is secured in place within stillage 20 and stillage 20 is then lifted by straddle carrier C of Figure 3 onto the bed or 2 0 tray of a suitable motor vehicle, such as a truck having a flat bed or tray, before stillage is itself secured to the truck. However, the truck may be provided with an upright frame permanently mounted to the vehicle loading area, such as by being welded or bolted directly to the flat bed or tray, whereby individual panels are instead directly loaded onto the bed or tray and then individually or collectively secured with respect to 25 the frame.

In either case, each panel 2 is arranged in parallel with the vertically extending frame 22 so as to extend vertically as this occupies a minimum footprint. For example, as shown in Figure 1D, the innermost external wall panel 10 is arranged at one side ofthe 30 frame 22 to be supported thereat, and the internal wall panel 12 is arranged at the other side of the frame 22 to be supported thereat. Subsequently, further panels are then arranged next to and in parallel with, either of panel 10 or 12, with these subsequent panels then being indirectly supported by the frame by being in abutting face-to-face relationship with adjacent panels on the same side of frame 22.

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- 14 In one form, to provide for a generally balanced stillage unit when laden, panels 10 and 12 can be loaded in an alternating manner on either side of the frame 22, or the same number of each of panels 10 and 12, in no particular order, or randomly, can be loaded on each side of the frame 22. As a further alternative, the typically heavier external panels can have a lesser number loaded on one side to be offset by a greater number of the lighter internal panels loaded on the other side. The optimal loading can be determined by operators at the factory.

The stillage unit 20 also comprises a panel securing arrangement comprising a io securing mechanism in the form of a winch and a securing element in the form of a strap 40. In one form, there is a dedicated securing arrangement for each panel. Each panel strap 40 takes the form of a more or less continuous loop that is connected to an upper hooked end 42 that is in turn hooked over to connect to the upper bar 28 of the stillage frame 22 to hang freely therefrom. In this configuration, straps 40 hang down from stillage top bar 28 when not in use as shown more particularly in Figures 1B and 1E.

Each strap 40 can be used to secure a respective panel 2 with respect to frame 22 and, in use, to secure its panel at the vehicle loading area. For example, a shorter

0 panel may be secured with a single strap, whereas a longer panel may require two spaced straps. In either case, the panels remaining on the vehicle can be held securely, whilst adjacent panels are being loaded or unloaded.

Each strap 40 is usually of a fixed length but, in a variation, may be of a variable or adjustable length. Each strap 40 is able to be passed over an outwardly facing surface of its respective panel. Further, a free end of each strap can then be fastened at decking 24 of stillage unit 20, or at the bed/tray of the vehicle, to secure its respective panel with respect to the frame 22. As explained below, in one form, this fastening can be facilitated by a winch 50 located on the longitudinal side of deck 24. It is to be noted that the spacing of the hooks for fastening the hooked end of straps 40 corresponds to the spacing of winches 50 along the longitudinal side of deck 24, so as to be in respective alignment therewith.

Each strap 40 has sufficient length such that it can be passed through a given strapping space S defined between adjacent decking panels 39 of decking 24, or

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- 15 through an aperture defined at the bed/tray of the vehicle. This enables the strap to be passed under its respective panel, and enables the strap free end to be fastened at the decking (or vehicle bed/tray) at an opposite side of the frame 22 to where the panel is located typically by winch 50 which is located on the opposite side of deck 24 to the side on which the panel being secured by strap 40 is located.

In the stillage unit 20 as illustrated in Figures 1Ato 1G and 2, the free end of strap 40 is fed to winch 50 located within a side C-channel section 36 of the decking framework (see the detail of Figure 1G). It will also be seen (Figures 1B & 1C) that each winch 50 io is aligned with a given one of the strapping spaces S, to facilitate feeding of strap 40 to respective winch 50.

Once a given strap 40 has been fed through a given winch 50 by the strap free end being looped around the winch, the winch can be actuated, such as by being manually 15 ratcheted in use to apply tension to, as well as to maintain tension in, the strap. This pulls the respective panel towards frame 22 and secures the panel at or with respect to frame 22.

It will also be seen that, at certain connection points of the decking framework, lifting 2 0 points in the form of twist lock couplings 60 are spaced out along opposing sides of the decking 24. Each twist lock coupling 60 is configured to be releasably but securely coupled to a respective male coupling element M located at the end of a chain linkage L of the crane or carrier C (see Figure 3). This allows the crane or carrier to lift the stillage unit 20 onto or off the vehicle loading area, such as the truck bed or tray. Each 25 twist lock coupling 60 is also employed to releasably couple and secure the decking 24 to suitable coupling elements located at suitable locations on the transportation vehicle.

Stillage unit 20 is configured to allow panels 2 to be generally arranged to extend in 30 substantially vertical orientation and to stack in side-by-side face-to-face relationship to one another, whereby panels 2 can then be safely and securely transported, stored and unloaded from such an orientation. This orientation maximises the number of panels that can be transported, thereby maximising volume utilisation efficiency on a transportation vehicle. In addition, the vertical, side-by-side face-to-face orientation can 35 help to facilitate loading and unloading of each panel, thereby minimising cycle time in

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- 16 loading and unloading.

It should also be noted that external wall panels tend to have a different construction to internal wall panels, and are generally thicker than internal wall panels (and typically heavier for the same given length). Hence, for a given length, it should be noted that more internal wall panels 12 can be loaded and stacked in side-by-side orientation on the stillage unit 20 than can be external wall panels 10.

A number of laden stillage units can also be stored at the factory or worksite, until the io panels held thereon are required for use. This can reduce or eliminate road vehicle demurrage. The stillage unit 20 also allows for better handling and safer, more secure transporting of multiple panels, especially large sized panels. In addition, because the laden stillage unit is able to be loaded and unloaded with panels at ground level, it can also reduce or avoid risks associated with working at height, which risks can otherwise 15 arise when securing crane linkages to panels located on the bed or tray of a vehicle, or when releasing panel load restraints at a vehicle.

The stillage unit 20 is designed to be deployed with a crane or carrier, such as a straddle carrier C, as shown in Figure 3. The crane or carrier can be located at the

0 panel fabrication facility, such as at a factory, to lift the stillage unit 20 and/or individual panels onto the vehicle loading area. The unit 20 can then be releasably secured to the bed or tray of the truck, as explained below. Another crane or carrier, such as a mobile crane or another straddle carrier located at the worksite can lift the stillage unit 20 or can lift individual panels off the vehicle loading area, once the vehicle is located 25 at the worksite.

Example

A non-limiting method of deploying stillage unit 20 as described above, will now be 30 provided.

The method comprises prefabricating at a factory or other production site, a number of shorter and longer length panels such as panels 10 and 12, at a factory. These panels are finished at the factory so as to be ready to be deployed on a worksite. In this 35 regard, at a house construction, some of the panels are external wall panels and some

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- 17 are internal wall panels. Each finished panel is then lifted in turn by an overhead crane at the factory onto stillage unit 20.

In one form, first panel 10 is lifted onto decking 24 to be located adjacent to frame 22 so as to stand vertically on a long panel edge. One or two straps 40’ (depending on panel length) are passed over an outwardly facing surface of first panel 10. Each strap 40’ is then passed through a strapping space S defined between adjacent decking panels 39 of decking 24, and then fed under panel 10. The loop of each strap free end is then fed into a respective aligned winch 50’ located at the opposite side of the o decking to the first panel 10. Figure 2 illustrates this direction of feeding of strap 40’ by arrows F.

Once the strap 40’ is connected to winch 50’, the winch is actuated, such as for example, by being mechanically ratcheted or motor driven to apply tension to, and also 15 to maintain tension in, strap 40’. This pulls the panel towards and secures it against frame 22.

Thereafter, a second panel 12 is lifted onto the decking 24 to be located adjacent to the frame 22 on the opposite side to panel 10 which is arranged to be standing

0 vertically on its long panel edge. A strap 40” is passed over an outwardly facing surface of the panel 12. The strap 40” is again passed through a strapping space S of the decking 24, and is then fed under the panel 12. The loop of the strap free end is again fed into an aligned winch 50” located at the opposite side of the decking to the panel 12. Again, once strap 40” is connected to winch 50”, the winch is actuated to 25 apply tension to, and maintain tension in, the strap 40”, and to pull the panel 12 towards and secure it against the frame 22.

This procedure is then repeated for successive panels, with each panel being pulled towards and secured against the next adjacent inwardly located panel when its respective strap(s) is tightened. The procedure is continued until up to six to ten prefabricated panels are so located and secured on the stillage unit 20. The number of panels, and the loading of the panels 10, 12 on either side of frame 22, is determined by an operator to ensure that the stillage unit 20 is generally evenly laden (i.e. weight/load balanced) on either side of the frame 22 to assist in lifting and transporting 35 the loaded stillage.

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- 18 Once the stillage unit 20 has been fully loaded, the laden unit is then connected to the straddle carrier C. In this regard, respective male coupling elements M at the end of each chain linkage L are respectively coupled to the intermediate or end twist lock couplings 60 of the decking 24. The carrier C then lifts and transports the laden stillage unit 20 either into a storage facility at the factory, or onto the back of a truck flat bed or tray. The coupling elements M are then detached, and each twist lock coupling 60 is then re-employed to couple and secure the decking 24 of the unit 20 to suitable coupling elements provided at the truck flat bed or tray. The stillage unit 20 is now io secured to the truck, ready to be transported to a worksite.

Having been transported to a site, the laden stillage unit 20 is then usually lifted by a crane or a straddle carrier off the back of the truck flat bed or tray and to a location adjacent to the building structure at the construction site or at the worksite. The one or 15 more straps 40 holding a given panel are then released, and the given panel then individually lifted by a crane directly from the stillage unit 20 and into place on the building.

In a variation, the laden stillage unit 20 can be left secured on the truck flat bed or tray, 2 0 and individual panels lifted by a crane directly off the stillage unit 20 whilst was still secured to the truck. By this manner the truck is able to return to the factory having deposited the load from its unit 20. This variation was also able to be employed when the frame 22 forms an integrated part of the truck flat bed or tray.

Whilst a number of embodiments have been described, it should be appreciated that the apparatus, system and method may be embodied in many other forms.

Another embodiment of the support structure in the form of a stillage will now be described with reference to Figures 4 to 7.

This form of stillage, generally denoted as 120, has a first generally upright frame assembly 122 located along the central longitudinal axis of stillage 120 and a generally horizontally oriented deck assembly 124 forming the base of stillage 120. Framework assembly 122 and deck assembly 124 extend generally perpendicularly to one 35 another.

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- 19 Framework assembly 122 comprises a multitude of framework members interconnected together which include a multitude of generally vertically extending posts 126 arranged in a line corresponding to the central longitudinal axis of stillage

120 at spaced apart locations. Six such posts 126 are illustrated, being two end posts

126a, and four intermediate posts 126b. A longitudinally extending upper framework member in the form of an upper support bar 130 extends between the upper ends of both end posts 126a as does a longitudinally extending lower framework member in the form of a lower support bar 132, extends between the lower ends of both posts io 126a in contact with deck 124.

A set of five inclined braces 136 extend between upper bar 130 and lower bar 132 from the upper corner of one post 126 to the lower corner of an adjacent post 126 where the posts meet upper and lower bars, respectively. In one form, braces 136 are alternately 15 oppositely inclined to provide increased strength and rigidity. Posts 126 and braces 136 divide stillage 120 into five sections. However, the stillage can have any number of sections.

Top rod 140 is provided along the upper surface of upper support bar 130 in alignment 2 0 with upper support bar 130 to extend longitudinally. A multitude of spaced apart generally planar brackets 142 are provided along the length of rod 140 to fixedly connect rod 140 to bar 130 as shown more particularly in Figures 4 and 7.

In one form, planar bracket 142 is of a generally irregular hexagonal shape having a 25 longer flat base, a shorter top, two short lower straight sides, two oppositely inclined upper sides, and an upper centrally located aperture.

In one form, bracket 142 having an aperture is an intermediate top tie plate whereas another form of the bracket not having an aperture is an end top tie plate 144 for 30 location at either front and rear end provided at the top of posts 126a for retaining rod 140 securely in place.

A space or gap 146 is located intermediate rod 140 and upper bar 130 for receiving a suitable securing arrangement (to be described in more detail later.)

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- 20 Deck assembly 124 is also of a generally rectangular shape having a pair of longitudinally extending side framework members 150, one on either side, and a pair of transversely extending end framework members 152, one at either end interconnected together. A multitude of intermediate transversely extending framework members 154 5 are arranged in spaced apart relationship to extend between the two side framework members 150 in parallel relationship to ends 152. Although eight intermediate transverse members 154 are shown, there can be any suitable or convenient number of intermediate members depending on the longitudinal length of stillage 120.

io A row of spaced apart stanchion holders in the form of stanchion pockets 156 are provided at spaced apart locations over the length of each of the side framework members 150 at either side of deck assembly 124.

A row of spaced apart upwardly extending stakes in the form of stanchions 158, are 15 provided along each longitudinal side of deck assembly 124 to extend from longitudinal side frame members 150. Although ten stakes 158 are shown in Figures 4 to 7, any suitable or convenient number of stakes can be used. Stanchions 158 are received in respective stanchion pockets 156.

0 In one form, stanchions 158 act as fall protection if the need arises for an operator, such as a workman, to stand on the stillage whilst it is located on the back of the motor vehicle, such as the flat bed of a tray truck. In one form, a protective barrier, typically in the form of a webbing material such as polyester webbing or strapping (not shown) is threaded through a suitable received located at or near to the top of each stanchion.

In one form, the receiver is a bracket (not shown) welded to the top of each stake to retain the webbing in place collectively along the side of the stillage. If a person should accidentally fall from the stillage, the webbing being held between the brackets restrains the person from falling off or over the stillage.

A generally planar rectangular end plate 160 is provided at each corner of deck assembly 124 to increase strength and rigidity of deck assembly 124.

A pair of spaced apart openings in the form of forklift pockets 162, are provided in each 35 longitudinal side framework member for receiving the ends of tynes of a forklift to assist

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- 21 in lifting stillage 120.

Operation of stillage 120 is essentially the same as operation of stillage 20.

A further embodiment of the stillage will now be described.

This form of the stillage, denoted generally as stillage 220 is similar to the form of stillage 120, apart from having a different base assembly in the form of a decking assembly, generally denoted as decking 224.

io

Decking 224 is provided with a pair of longitudinally extending side rails 230 and a pair of transversely extending end rails 232 interconnected together to form a rigid rectangle frame. The size, shape and configuration of deck 224 is selected to cooperate with an outer deck frame assembly or outer deck 210. In one form, deck 15 224 is received within outer deck 210. In this embodiment, one form of outer deck 210 is the base of a shipping container, particularly a single shipping container. However, in other embodiments, stillage 220 is of a size corresponding to the length of a double shipping container.

0 In this embodiment, outer deck assembly 210 includes a pair of longitudinally extending side rails 212, one on either side of outer deck 210, and a pair of transversely extending end rails 214, one at either end so that side rails 230 are in alignment with side rails 212 and end rails 232 are in alignment with end rails 214. Stakes 212, in the form of stanchions 216, extend upwardly from side rails 212 of outer 25 deck 210.

Other parts of stillage 220 are similar to corresponding parts of stillage 120 and operation of stillage 220 is similar to that of stillage 20 and stillage 120.

Stillage 220 is designed to correspond to the base of a shipping container or to be connectable to the base of a shipping container so as to benefit from being able to use the same material handling equipment and techniques that have been developed for handling shipping containers, particularly loading and unloading the shipping containers and transporting the shipping containers by road going vehicles, particularly 35 existing vehicles dedicated to transporting shipping containers.

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- 22 By the stillage having the same dimensions as the base of a shipping container and the stillage being provided with compatible fittings to those provided on the base of the shipping container conventional equipment, machinery and vehicles using established 5 lifting and transporting techniques can be used thereby reducing the cost of providing specialised equipment and improving efficiency of the handling operation, particularly loading and unloading operations.

In the claims which follow, and in the preceding description, except where the context io requires otherwise due to express language or necessary implication, the word “comprise” and variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the apparatus, method and system as disclosed herein.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims (22)

1. A module for containing at least one structural element having an outer

5 surface, the module comprising a planar base assembly having a first side portion and a second side portion, the base assembly for supporting the module when the base assembly is located on a substrate for transportation of the module, io a support assembly for supporting the at least one structural element in a desired orientation of the structural element, the support assembly connected to the base assembly to extend outwardly from the base assembly to divide the base assembly into the first side portion located on one side of the support assembly and the second side portion located on the other

15 side of the support assembly, the first side portion and the second side portion being opposite side portions of the base assembly, and a securing arrangement to secure the at least one structural element to the module,

2 0 the securing arrangement including a flexible securing element having a first end and a second end and an actuator for operating the flexible securing element to secure the structural element to the module, the flexible securing element extending between the support assembly at or towards the first end thereof and the base assembly at or towards the second end

25 thereof wherein when the flexible securing element extends between the support assembly and the base assembly the flexible securing element is in contact with the outer surface of the at least one structural element and passes from the first side portion of

30 the base assembly to the second side portion of the base assembly underneath the structural element to retain the structural element in the desired orientation against the support assembly.

2. A module according to claim 1 in which the planar base assembly is arranged 35 to extend substantially horizontally and the support assembly is arranged to extend

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- 24 substantially vertically extending upwardly from the base assembly.

3. A module according to claim 1 or 2 in which the at least one structural element is a prefabricated building component in the form of an engineered building

5 component, a panel, a sheet, or board including a composite board, a laminated board, or an autoclaved aerated concrete panel, slab, sheet, or block.

4. A module according to claim 3 in which the building component is a prefabricated wall panel, either an internal wall panel or an external wall panel having io at least one part which is an autoclaved aerated concrete panel.

5. A module according to any preceding claim in which the substrate is a motor vehicle or part of a motor vehicle including the loading deck of a motor vehicle, the truck tray of a motor vehicle, or flat load bed of a motor vehicle or a holding facility, a

15 loading area, a loading pad, a storage area, a warehouse, a factory floor, a storage racking, a worksite, a construction site, or a building site.

6. A module according to any one of the preceding claims, wherein the at least one structural element is multiple structural elements and the securing arrangement

2 0 includes multiple flexible securing elements wherein each of the multiple structural elements is secured with at least one flexible securing element.

7. A module according to any one of the preceding claims in which the support assembly includes an upper support member wherein the first end of the flexible

25 securing element is either fixedly attached or releasably attached to the upper support member of the support assembly to anchor the flexible securing element.

8. A module according to any preceding claim in which the first side of the base assembly further includes one or more apertures or spaces wherein the flexible

30 securing element passes through one of the apertures or is received in one of the spaces enabling the flexible securing element to pass under the respective structural element, and wherein the second end of the securing element is fastened to the base assembly or to the vehicle loading area on the opposite side of the support assembly on which the respective structural element is securely located.

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9. A module according to any preceding claim, wherein the flexible securing element is in the form of webbing, belting, strapping, tape, rope, ribbon, nylon, cord, strap, polyethylene fibres, polypropylene fibres, a net octopus strap, or interconnected network of flexible lengths.

10. A module according to any preceding claim in which the actuator is a winch including a manually actuated winch or a motor driven winch or a ratchet having a handle for rotating the ratchet.

io

11. A module as claimed in claim 10, wherein the flexible securing element is a strap or webbing in the form of a loop, arranged so that the second end of the strap is able to be looped over the winch or ratchet located on the base assembly or located on the vehicle loading area, wherein the winch or ratchet is actuated in use to apply tension to and maintain tension in the strap or webbing to secure the respective

15 structural element to the module in the desired orientation with respect to the support assembly

12. A module according to any preceding claim in which there are two or more individual securing arrangements for securing each structural element or for securing

2 0 all structural elements.

13. A module according to any one of claims 10 to 12 in which the first side portion and the second side portion of the base assembly are longitudinally extending side portions wherein one or more of the winches are fixedly attached to the lengthwise

25 extending edges of the side portions of the base assembly in spaced apart relationship to each other.

14. A module according to any preceding claim in which the flexible securing elements are connected to the support assembly by spaced apart hooks in which each

30 hook suspends one flexible securing element.

15. A module according to claim 14 in which the spacing apart of the hooks for fastening the flexible securing elements corresponds to the spacing apart of the winches so that the hooks for fastening respective ones of the first ends of the flexible

35 securing elements are in alignment with the respective winches to receive the

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- 26 respective second ends of the respective flexible securing elements.

16. A module according to any one of claims 8 to 15 in which the base assembly includes a floor wherein the apertures or spaces are provided through the floor of the

5 base or the apertures or spaces are defined at or within the vehicle loading area.

17. A module according to any preceding claim in which the flexible securing element includes a ratchet tie down strap made from polyester in which the second end of the strap is threaded through the ratchet, rolled up and secured in the module io during transportation of the module.

18. A module according to any one of claims 5 to 17 in which the support assembly extends centrally along the loading area of the vehicle and the structural element includes multiple structural elements secured on either side of the support assembly

15 including multiple panels on each side of the support assembly.

19. A module according to any preceding claim in which the support assembly comprises a generally vertically extending upright supporting structure or support framework of an elongate frame comprising a multitude of interconnected framework

2 0 members for receiving the structural elements in the form of prefabricated walls, panels or sheets, wherein the panels are arranged collectively in parallel with the vertically extending support frame and/or with each other.

20. A module according to any one of claims 7 to 19 in which the upper support

25 member is an upper support rod and an upper support bar in which the upper support rod is aligned along the upper surface of the upper support bar to extend longitudinally therewith and a multitude of spaced apart planar brackets provided along the length of the upper support rod to fixedly connect the upper support rod to the upper support bar wherein the planar bracket is ofan irregular hexagonal shape having a longer flat base,

30 a shorter top, two short lower straight sides, two oppositely inclined upper sides, and an upper centrally located aperture.