GB2092640A - Portable building unit - Google Patents

Abstract

The unit comprises a structural metal frame having a pair of lateral vertical sub-frames (11a, 11b), each of said sub-frames including an upper member (12a, 12b) and a lower member (13a, 13b) the upper and lower members of each sub-frame being interconnected by uprights (14a, 14b), and the lower members (13a, 13b) of the sub-frames being rigidly interconnected in spaced apart parallel relation by frame cross members (15) which extend between the lower members and the upper members of the sub-frames being interconnected solely by one or more roof panels each of which extend between and is secured to the upper members (12a, 12b) of the sub- frames (11a, 11b), a floor structure extending between and being supported by the lower members of said sub-frames. <IMAGE>

Description

SPECIFICATION Portable building unit This invention relates to a portable building unit which may be assembled with further similar units to provide a building construction. Each unit is fully factory assembled for delivery to a prepared site in an assembled condition complete with at least floor and roof.

More particularly, the or each unit comprises a structural metal frame to which the floor and roof structures are attached. Where such units are to be assembled together to form a multi-unit building construction the structural frames are butted or otherwise connected together in the desired arrangement.

In the factory or on-site end walls and side walls are secured to the frame, one or more of such end or side walls being omitted if required, to permit full width linking or end-to-end linking of two or more of the units.

Such portable building units will hereinafter be described as "of the type described".

An object of the invention is to provide a new and improved portable building unit of the type described.

According to the present invention we provide a portable building unit of the type described comprising a structural metal frame comprising a pair of lateral vertical sub-frames, each of said sub-frames including an upper member and a lower member, the upper and lower members of each sub-frame being interconnected by uprights, and the lower members of the sub-frames being rigidly interconnected in spaced apart parallel relation by frame cross members which extend between the lower members, and the upper members of the subframes being interconnected solely by one or more roof panels, the or each of which extend between and is secured to the upper members of said sub-frames, a floor structure extending between and being supported by the lower members of said sub-frames.

It has been found, that the roof panel or panels can provide sufficient strength to hoid the subframes rigidly apart at their upper ends and thus serve a similar function as a metal frame cross member would. It has been found further, that this construction has advantages compared to conventional structures having metal cross members because cold bridging is reduced, timber being a better insulator than metal, and thus condensation, which can occur in metal framed buildings, is also reduced. Another advantage with this construction is that the structure is considerably simplified and costs in producing such building are accordingly reduced.

Said sub-frames may define open sides of the unit whereby two or more similar units may be joined together in side-by-side relation with full width linking, but one or more side wall panels may be secured to the frame so as to provide a unit with walls at one or both sides. Alternatively, or additionally, two or more units may be connected in end to end relation, if required.

Preferably, the or each side wall panel is secured to the outside of the associated vertical sub-frame so that the members which comprise the associated sub-frame are inside the side walls, and the or each end of the unit may be closed by one or more end wall panels. The or each end wall panel may be received substantially entirely within an end opening defined between the sub-frames so that the members which make up the subframes lie peripherally of the side wall panel and wholly external to the habitable volume of the unit.

Conveniently the or each end wall panel may be secured directly to the upright members of said sub-frames.

Desirably, lateral marginal portions of the roof panel and floor structure extend into the end and/or side openings defined by said sub-frames.

The or each roof panel may comprise a structural sandwich including an inner metal sheet and an outer timber decking, sandwiching therebetween a thermally insulating infilling. The infilling may be bonded to the inner and outer sheets and may be a rigid foamed or expanded plastics material. The roof panel may have a timber framework, to which the inner and outer sheets are secured. The outer sheet preferably comprises ply-wood, and a waterproof membrane may be provided over the roof panel and around the upper frame members to which the roof panel is secured.

The end and/or side wall panels may be of similar construction to the roof panel or panels described above but the inner sheet may comprise plaster board or the like instead of metal as with the roof panel, if desired.

The floor structure may comprise a timber decking supported by a plurality of timber joists which extend between and are carried by the lower members of the sub-frames, with thermal insulation between such joists, such as a layer of glass fibre or other similar material supported on suitable panels positioned between the joists.

Preferably, the decking, which may be of chip board or the like, extends across the upper faces of the lower members of the sub-frames, whilst the joists extend between and are secured to the inner faces of such lower members.

Conveniently, the lower members and the upper members of the sub-frames each comprise channel section steel beams arranged with the webs thereof extending vertically and the flanges extending horizontally although other types of beams may alternatively be utilised.

The upright members of each subframe are preferably connected to the ends of the upper and lower members of the sub-frames. Such upright members may comprise channel section steel columns although again, other constructions are possible.

The ends of the upper and lower members may be each butted against a column and secured to the column in any suitable manner, for example, by means of an angle bracket bolted to the web of the upper or lower member as appropriate and to the inner flange of the channel section column.

Lifting attachments may be secured to the upper members or uprights of each sub-frame, preferably at respective positions immediately adjacent to the joint between the respective column and upper member.

The frame cross members which connect the lower members of the sub-frames preferably are connected to the sub-frames, at locations adjacent the lower corners thereof. The cross members may each comprise a channel section beam, preferably arranged with the web thereof extending vertically and the flanges directed horizontally.

It will be observed that where two units are connected in side by side relationship the floor, roof and end wall structures of the unit are disposed entirely within the metal frame, so that the interior of the unit is free substantially from inwardly protruding beams, and thus alleviating "cold bridging" which otherwise establishes a heat-loss path between the interior of the unit and the metal frame through these structures.

The invention will now be described by way of example with reference to the accompanying drawings wherein FIGURE 1 is a partial transverse cross-sectional view in a vertical plane through a building unit embodying the invention; FIGURE 2 is a partial longitudinal section on a vertical plane; FIGURE 3 is a horizontal section through an end wall of the unit, also illustrating the manner in which two adjoining units may be secured together; FIGURE 4 is a perspective view of a rigid metal frame on which the building is constructed; and FIGURE 5 is a fragmentary side view showing an inside detail of a corner joint in such frame.

Referring to the accompanying drawings, a building unit in accordance with the invention comprises a rigid frame 10 as shown in Figure 4, preferably constructed from channel section steel beams. The frame 10 comprises two vertical subframes 1 1 a, 1 1 b, each comprising respective upper horizontal beams 1 2a, 1 2b and lower horizontal beams 1 3a, 1 3b interconnected at their ends by uprights 1 4a, 1 4b. The two vertical subframes 1 1 a, 1 1 b are connected together by cross members 1 5 which extend between the lower beams 1 3a, 1 3b at positions adjacent but spaced from the uprights 1 4a, 1 4b.

The upper and lower beams 1 2a, 1 2b, 1 3a, 1 3b are each of channel shape in cross-section and each includes a vertically disposed web 1 6 (see Figure 1), the upper beams 1 2a, 1 2b having outwardly directed horizontal flanges 1 7 and 1 8, and the lower beams 1 3a, 1 3b inwardly extending flanges 1 7a, 1 8a.

The uprights 1 4a, 1 4b are also of channel shape in section, and each includes a web 1 9 (Figure 5) and outwardly directed flanges 20 and 21.The flanges 17, 18, 17a, 18a, 20 and 21 all incorporate inwardly directed lips.

To enable the beams 1 2a, 1 2b, 1 3a, 1 3b and uprights 1 4a, 1 4b to be connected rigidly together, the beams 1 2a, 1 2b, 1 3a, 1 3b are butted directly against the uprights 1 4a, 1 4b and secured by means of an angle bracket B bolted to the web 1 6 and flange 20 of the uprights 1 4a or 14b.

Alternatively an end portion of the flanges may be cut away at one side, to enable the end portion of the flange 1 9 of each upright 1 4a to be brought into face-to-face relation with an end portion of the web 1 6 of the adjacent beam, and the two webs directly bolted together. If desired, a corner plate may additionally be bolted to the webs of the beams and uprights.

The cross members 1 5 are also of channel shape in section, as seen in Figure 5, and each comprises a vertical web 23 with horizontally inwardly directed flanges 24 and 25, each having downwardly directed lips 24', 25' respectively at their free edges. An end portion 26 of the web 23 is turned inwardly and bolted directly to the web 1 6 of the adjacent beam 1 3a, 1 3b.

It will thus be seen that each sub-frame 11 a, 11 b affords a rectangular aperture defined by the beams 1 2a,12b,13a,13b and uprights 1 4a, 1 4h, for the reception of end and side wall panels as hereinafter described.

Lifting eyes 27 are secured to the tops of the uprights 1 4a, 1 4b by bolts 27a which engage a turned over lip of the flange 20 thereof, and a reinforcing angle 27b as shown in Figure 2.

Referring now to Figures 1 to 3, the unit illustrated includes a floor structure 30 comprising an upper sheet of chip board 31 which rests at its lateral margins on the upper flanges of the lower beams 1 3a, 1 3b and is supported on the cross member 1 5 and further by transversely extending wooden joists 32, which joists are secured directly to the webs 1 6 of the beams 1 3a, 1 3b. Layers of fibre glass or other similar mineral wool insulation 33 are supported between the wooden joists 32 on bitumen impregnated fibre board sheets 34 which themselves rest in position on staples 35 driven into the joists 32.The joists 32 are additionally supported at their ends on angle section members 36 carried by the webs of the lower beams 13a, 13h.- To enable the whole structure to be supported on a lorry affording a bed narrower than the overall width of the building unit, longitudinal bars 37 are secured in position beneath the joists 32.

A roof panel 40 is secured below the upper beams 1 2a, 1 2b by attachment to the lower flanges 17 thereof. The roof panel 40 comprises an inner skin 41 of plastic coated steel and an outer sheet 42 of plywood secured on a timber perimeter framework part of which is shown at T with the space between them filled by a foamed plastics material 43. A waterproof membrane 44 is provided across the upper face of sheet 42, and may also extend around the beams 1 2a, 1 2b, although as shown, a cap of weatherproof membrane W caps the beams 1 2a, 1 2b in the manner of a trim strip.

It can be seen that the vertical sub-frames 1 1 a, 1 b of the rigid frame 10 are connected at the bottom by the cross members 15, although no frame parts interconnect the sub-frames 11 a, 1 b at the top.

It has been found, surprisingly, that the roof panels 1 4 described provide sufficient strength to hold the sub-frames 11 a, 1 b rigidly apart at their upper ends and thus serve a similar function as a metal frame cross member would. This is particularly due to the perimeter members T of the panels 40. It has been found further, that this construction has advantages compared to conventional structures having metal cross members because cold bridging is reduced, timber being a better insulator than metal, and thus condensation, which can occur in metal framed buildings, is also reduced. Another advantage with this construction is that the structure is considerably simplified and costs in producing such building are accordingly reduced.

Secured to the frame are end wall panels 50 and side wall panels 60, although one of the end wall panels 50 and/or side wall panels may be omitted to enable the unit to be linked to other similar units, to provide a multi-building construction, by bolting the sub-frames of such adjacent units directly together to bring the floors and end wall panels of such units into direct abutting relation as shown in Figure 3.

The end wall panels 50 are secured to the inside of the uprights 1 4a, 1 4h by attachment to the inner flanges 20 thereof so that the panels 50 are received entirely within the metal frame 10.

Such end wall panels comprise an outer sheet 51 of coated steel, and an inner sheet of plasterboard 52 secured to a framework of timber members 53 and with a layer of foamed plastics insulation material 54 inbetween.

The end and side wall panels 50, 60 add further rigidity to the structure. Where two or more units are linked, an internal trim strip 55 may be provided if desired to cover the joint between adjacent end or side wall panels 60, 50.

Whilst one side of the illustrated unit in Figure 3 is left open to provide a full width connection with an adjacent similar unit, the other side is closed by means of a side wall panel 60 (Figure 1) attached to the vertical frame 11 a, externally thereof. The side wall panel 60 is of similar construction to the end wall panel 50 and includes an outer sheet 61 of coated steel, and an inner sheet of plasterboard 62 secured on a timber subframe of which are shown at T' with foamed insulation material 64 between the inner and outer sheets 62, 61.

The edges of the side and end wall panels may be masked by appropriate trim strips, 58, 59, 67, 68 and 69 as indicated.

Although not so shown, the end and side wall panels where provided may be equipped with all necessary door and windows, and the windows may be single or double glazed as required.

All required internal fittings, including partition walls, carpeting or other floor covering, and appropriate mains services such as gas, electricity, water supply and sanitation may be provided so that the complete unit may be delivered to a prepared site, ready for use, subject only to securing adjacent units together where necessary and applying internal trim strips as necessary at the joints between adjacent units, and if required external trims.

Although not evident from the drawings, the roof structure slopes slightly from end to end, to facilitate drainage. To achieve this, the vertical uprights 1 4a, 1 4b are longer at one end. When two or more units are connected together in end to end configuration, the higher ends may be adjacent, with suitable guttering being provided at the lower ends.

Claims (1)

1. A portable building unit of the type described comprising a structural metal frame comprising a pair of lateral vertical sub-frames, each of said sub-frames including an upper member and a lower member, the upper and lower members of each sub-frame being interconnected by uprights, and the lower members of the sub-frames being rigidly interconnected in spaced apart parallel relation by frame cross members which extend between the lower members, and the upper members of the sub-frames being interconnected solely by one or more roof panels each of which extend between and is secured to the upper members of said sub-frames, a floor structure extending between and being supported by the lower members of said sub-frames.

2. A unit according to claim 1 wherein said subframes define open sides of the unit whereby two or more similar units may be joined together in side-by-side relation with full width linking.

3. A unit according to claim 2 wherein one or more side wall panels is or are secured to the frame so as to provide a unit with a side wall at one or both sides.

4. A unit according to claim 3 wherein the or each side wall panel is secured to the outside of the associated vertical sub-frame so that the members which comprise the associated subframe are inside the side walls.

5. A unit according to any one of the preceding claims wherein the or each end of the unit is closed by one or more end wall panels.

members which make up the sub-frames lie peripherally of the side wall panel and wholly external to the habitable volume of the unit.

7. A unit according to Claim 6 wherein the or each end wall panel is secured directly to the upright members of said sub-frames.

8. A unit according to any one of the preceding claims wherein lateral marginal portions of the roof panel and floor structure extend into the end and/or side openings defined by said sub-frames.

9. A unit according to any one of the preceding claims wherein the or each roof panel is located below the upper frame members, so that the upper frame members are wholly external to the habitual volume of the building.

10. A unit according to any one of the preceding claims wherein the or each roof panel comprises a structural sandwich including an inner metal sheet and an outer timber decking, sandwiching therebetween a thermally insulating infilling.

1 A unit according to claim 10 wherein the infilling is a rigid foamed or expanded plastics material.

12. A unit according to claim 10 or claim 11 wherein the roof panel has a timber framework to which the inner and outer sheets are secured.

13. A unit according to any one of claims 10 to 12 wherein the outer sheet comprises plywood, and a water-proof membrane is provided over the roof panel and around the upper frame members to which the roof panel is secured.

14. A unit according to claim 10, 11 or 12 wherein the end and/or side wall panels are each of similar construction to the roof panel or panels.

15. A unit according to any one of the preceding claims wherein the floor structure comprises a timber decking supported by a plurality of timber joists which extend between and are carried by the lower members of the subframes, with thermal insulation between such joists, supported on suitable panels positioned between the joists.

1 6. A unit according to claim 15 wherein the decking extends across the upper faces of the lower members of the sub-frames, whilst the joists extend between and are secured to the inner faces of such lower members.

17. A unit according to any one of the preceding claims wherein the lower members and the upper members of the sub-frames each comprise channel section steel beams arranged with the webs thereof extending vertically and the flanges extending horizontally.

18. A unit according to any one of the preceding claims wherein the upright members of each sub-frame are connected to the ends of the upper and lower members of the sub-frames.

19. A unit according to any one of the preceding claims wherein the uprights comprise channel section steel columns.

20. A unit according to claim 1 9 wherein the ends of the upper and lower members are each butted against a column and secured to the column.

21. A unit according to any one of the preceding claims wherein lifting attachments are secured to the upper members or uprights of each sub-frame.

22. A unit according to any one of the preceding claims wherein the frame cross members which connect the lower members of the sub-frames are connected to the sub-frames at locations adjacent the lower corners thereof.

24. A unit according to any one of the preceding claim wherein said cross members each comprise a channel section beam arranged with the web thereof extending vertically and the flanges directed horizontally.

24. A portable building unit substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

25. Any novel feature or novel combination of features described and/or shown in the accompanying drawing.