GB2176820A

GB2176820A - Arched modular building

Info

Publication number: GB2176820A
Application number: GB08515539A
Authority: GB
Inventors: Leonard Blay
Original assignee: Individual
Current assignee: Individual
Priority date: 1985-06-19
Filing date: 1985-06-19
Publication date: 1987-01-07
Also published as: GB8515539D0

Abstract

The building has glass reinforced plastics panels, e.g. 5,6,7,8 arranged in adjacent arches. Each panel is four sided and has two inwardly directed parallel flanges 14 and two inwardly directed angled flanges 14' or 26,27. Adjacent flanges are connected together by rivets 16 and sealed together by caulking 17. Insulation may be provided inside the panels and enclosed by inner faces. <IMAGE>

Description

SPECIFICATION Modular building The present invention relates to a modular building.

There is a demand for a cheap, thermallyinsulated building particularly though not exclusively for growing mushrooms in. At present double skin plastics film tunnels are used for this with fibreglass blanket providing insulation between the panels. However the skins are susceptible of damage, which can i) degrade the insulating properties of the buildings, ii) render them difficult to clean to provide the high quality environment required and iii) provide access into the building for insects.

The present invention has been made with a view to providing an improved building particularly though not exclusively for mushroom growing.

A modular building of the invention comprises a plurality of flanged panels, each panel being four-sided, defining an outer face and having a flange at each side, the flanges on two opposite sides being parallel to each other and the flanges on the other two opposite sides being set at such an angle to each other that, when several panels are connected together by these angled side flanges, the panels form an arch.

Normally the building will be made up of a plurality of such arches connected to each other in the direction of the length of the building at the parallel side flanges. However, it is envisaged that the panels may be connected in the manner of "bonded" brickwork whereby continuous arches are not identifiable or at least extend stepwise over the building.

Such an arrangement necessitates end panels which are half of, or some other fraction to suit the bonding pattern, the length of the majority of the panels in their direction between their parallel side flanges.

Whilst it is envisaged that the panels will normally be all identical with each other, producing a regular-sided or circularly-curved structure in cross-section to its length; it is possible for panels having dissimilar lengths peripheral of their arch direction to be incorporated, for instance to produce a higher than the normal regular sided structure or wider than the normal regular sided structure.

Where the building requires to be insulated, the panels will be arranged with their flanges extending inwards and foam plastics insulating material applied, either by spray or as a block held in place by an adhesive. A durable finish covering the foam material may be provided by means of an inner face secured to each panel.

The invention provides in addition to the building per se a method of erection of a modular building of a plurality of flanged panels, each panel being four-sided, defining an outer face and having a flange at each side, the flanges on two opposite sides being parallel to each other and the flanges on the other two opposite sides being set at an angle to each other, the panels being connected together at their flanges to form a plurality of arches each extending laterally of the building and each being connected to its neighbour longitudinally of the building.

Preferably the flanges extend inwards and at least part of the space within the flanges of each panel is filled with foam plastics material secured to the outer face of each panel. The foam plastics material will normally cover first ones of panel fastening members, second ones of which are added subsequently to the positioning of the foam. Inner faces covering the foam may be secured by the second ones of the panel fastening members.

To help understanding of the invention, two specific embodiments thereof, with variants, will now be described with reference to the accompanying drawings in which: Figure 1 is a side view of a building of the invention in a first embodiment; Figure 2 is a cross-sectional view of the building of Figure 1 on the line ll-ll; Figure 3 is a cross-sectional view at an inter-panel joint on the line Ill-Ill in Figure 1; but insofar as the joint is similar at the line lll'-lll', Figure 3 could equally be regarded as a crosssection on this line with the panel faces suitably curved; Figure 4 is a scrap view similar to that of Figure 2 showing a variant; Figure 5 is a view similar to Figure 2 showing another variant; and Figure 6 is a scrap view similar to Figure 4 showing another embodiment of the invention.

Referring first to Figures 1 and 2, the building can be seen to comprise a plurality of glass reinforced plastics material panels 1,2,3,4 arranged in one arch, 5,6,7,8 arranged in a second arch, 9,10,11,12 arranged in a third arch and so on. Panels 7,8,11 and 12 are not visible in Figure 1, being behind panels 6,5,10 and 9 respectively. As may be seen in Figure 2, the panels have curved outer faces 13, which in this embodiment provide a continuous outer semi-circularly cylindrical about the longitudinal axis 0 shape to the "walls and roof" of the building. There being four panels in each arch of panels, each occupies a 45" sector about the axis, in the embodiment shown, though in other embodiments especially for larger buildings more panels per arch may be provided with each occupying a correspondingly smaller sector.In the direction of the axis, the outer faces 13 are recti-linear.

The sides of the panels have flanges 14,14' directed inwardly of the building. The flanges 14 at the sides spaced in the direction of the axis 0 are parallel with each other and at right angles to the direction of the axis. The flanges 14' at the sides spaced circumferentially of the axis are angled with respect to each other at 45', i.e. radially of the axis 0. This orientation of the flanges 14,14' provides that adjacent flanges of adjacent panels abut face to face. For securing together of the panels their flanges are connected by means of fasteners, peel or bifurcated rivets 15 as shown although other fastening means may be used such as nuts and bolts. A rubber washer 16 is positioned on each rivet between the flanges being connected.This washer forms the dual function of sealing the gap between the connected flanges from the through holes in the flanges for the rivets and of regulating the gap. Also between the gap at the outer and inner edges of the flanges and centrally thereof are three respective lines 17 of mastic caulking compound of the type supplied by Hydrodam of Havant, Hampshire under the name VULCEM 116. On spreading of the rivets, the mastic is squeezed to a thickness defined by the washers 16. The three lines are continuous along every flange, whereby total water tightness is provided.

Each of the flanges 14,14' has six rivets connecting it to its neighbour in a neighbouring panel, one pair at one flange end, one pair in the middle and one pair at the other end.

The pairs are well spaced across the width of the flanges. This arrangement provides structural integrity to the building. In this respect it should be noted that the individual flanges 14 of the panels in each arch form a continuous beam via the connections at the ends of their adjoining flanges 14', the adjoining flanges 14,14' in each panel at the panel corners being joined as an integral moulding. Where the connections between the panels cause too great a fall off in bending stiffness of beam of flanges 14, the latter can be locally deepened as shown in Figure 4.In a non-illustrated alternative, a half panel, e.g. of 20 , may be provided at one end of one arch and at the other end of the next arch-the other panels being of 40". In this way the "beam" joints in the one arch are "bonded" or bridged by a continuous flange in the next arch.

The insides of the outer faces 13 have foam plastic material 18 adhered thereto, for both thermal insulation of the building and stiffening of the panel faces. The foam material may be of urethane phenolic isocyanate for instance either sprayed in situ or pre-formed as a slab and glued in place. It should be noted that the outer ones of the rivets 15 are covered by the foam material.

Each panel, which with its outer face 13 and flanges 14,14' is in the form of a shallow open box, has an inner face 19 fitted into it to cover and enclose the foam material. The inner faces 19 have flanges 20,20' analogous to the flanges 14,14'. Between mating ones of the flanges 20 & 14 and 20' & 14' further mastic caulking material is provided, for sealing the interior space of each panel containing the foam material 18. This sealing is important for preventing ingress of water vapour and of insects. Further optional sealing may be provided with sealing strips 21 glued over the free edges of the flanges. The inner faces are actually secured in position by the inner ones of rivets 15 which pass through both the adjacent flanges 14 (or 14') and the abutting flanges 20 (or 20').It should be noted that despite the angling of the flanges 14' and 20', fitting of the inner skins is readily accomplished due to the flexibility of the inner face 19 and a 3mm sealing gap provided all around the inner face between its flanges 20,20' and the flanges 14,14' of the corresponding panel. Typically the panels will have a circumferential length of 2.35 m and an axial length of 1 m. The flanges 14,14' will be 150 mm wide and the flanges 20,20' will be 60 mm wide; a gap of average thickness of 5mm will be present between the insulation foam 18 and the inner face 19. Typically the building may be up to 50 m long.

The building is erected in the following manner. Firstly the panels 1 and 2 are riveted together at their neighbouring flanges 14', the caulking material 17 having been first placed on the flange 14' of one of the panels together with the washers 16 which may each be temporarily secured in position by a dab of mastic. Panels 3 and 4 are added in the same way to form the first arch. Then panel 5 of the next arch is added, it being connected via one of its flanges 14 to the neighbouring flange 14 of panel 1, with the interposition of the caulking material and using the rivets 15 and washers 16. The next panel 6 is added connecting one of its flanges 14 and one of its flanges 14' to the neighbouring panels in the panels 2 and 5 respectively. Thus the building is progressively assembled. It should be noted that only the outer rivets 15 are added at this stage.

Once it is sufficiently long, spraying or glueing in of the foam insulation material is started at the first arch. Then as this progresses, the inner faces 19 are added and secured by the inner ones of the rivets. Finally the sealing strips 21 are added, if required.

The structure is such that it can readily be cleaned, being of glass reinforced plastics material. Although painting would not normally be required when the building is used for horticultural purposes, it is convenient to use suitable coloured gel coats for the outer panels and inner faces.

The ends of the buildings may be closed with concrete block work and conventional access doors.

Turning now to Figure 5, this shows a variant of the building of Figure 1 wherein the individual panels have flat faces 25. The angled flanges 26,27 in each panel are not equally angled to the flat face 25 of the panel.

Rather, flange 26 is at right angles to the face 25 whereas flange 27 is at 60 to the face 25, making 30 between the flanges. The panels are assembled with alternately flanges 26 and 27 joined in pairs around each arch of the building whereby the cross-sectional shape of the building is semi-hexagonal. It should be noted that the flanges 26 and 27 have differing widths, but since they are joined in respective pairs this presents no mismatch. Figure 5 also shows securement of the building to its concrete foundations 28 via 0.6m high concrete block work 29 built partly on the foundation and partly with the bottom ones 30 of the panels. Ingress of water at the foundations is prevented by mastic caulking 31 at the outer edge of the bottom flanges of the panel 30.If a wide building is required, a special all right angle flange panel, not shown, may be incorporated at the ridge 32 of the building.

Figure 6 shows another embodiment of the invention in which the panels 50 are of similar outline shape to the panels of the Figure 1 building. However no inner face nor any insulation foam is provided. Rather the faces 51 of the panels have cut-outs 52 over which are riveted and mastic caulking sealed clear plastics material sheets 53. Thus light can enter the building and it can be used as a greenhouse. For ventilation, selected ones of the panels can be fitted with louvres (not shown) in place of the clear sheets 53. This building can be erected in the same sequence as the building of Figure 1.

The invention is not intended to be restricted to the details of the above described embodiments. For instance, the rivets may be replaced by nuts and bolts. The inner faces may be laid up in situ of glass reinforced plastics material and gel coat. It is also envisaged that for certain applications it may be adequate to provide the insulating foam without the inner faces.

Claims

1. A modular building of the invention comprising a plurality of flanged panels, each panel being four-sided, defining an outer face and having a flange at each side, the flanges on two opposite sides being parallel to each other and the flanges on the other two opposite sides being set at such an angle to each other that, when several panels are connected together by these angled side flanges, the panels form an arch.

2. A modular building as claimed in claim 1 comprising a plurality of arches, each incorporating a plurality of the panels and connected to each other in the direction of the length of the building at the parallel side flanges.

3. A modular building as claimed in claim 2 comprising end panels having a dimension between their parallel side flanges which is a fraction of the corresponding dimension in the majority of the panels or part panels having a dimension between their angled sides which is a fraction of the corresponding dimension in the majority of panels.

4. A modular building as claimed in claim 1, claim 2 or claim 3, wherein the panels have flat outer faces.

5. A modular building as claimed in claim 1, claim 2 or claim 3, wherein the said panels have curved outer faces.

6. A modular building as claimed in any preceding claim, wherein the panels at one position in the arch(s) have a different dimension between their angled flanges from the panels at another position in the arch(s).

7. A modular building as claimed in any preceding claim, wherein the flanges of the panels extend inwardly of the building and the space within the flanges of each panel has insulation applied thereto.

8. A modular building as claimed in claim 7, wherein the insulation is in the form of blocks held in place by adhesive.

9. A modular building as claimed in claim 7, wherein the insulation is in the form of foam material sprayed in situ.

10. A modular building as claimed in claim 7, claim 8 or claim 9, wherein the insulation is covered on its side internal of the building by an inner face to each panel.

11. A modular building as claimed in claim 10, wherein each inner face has two parallel flanges and two angled flanges mating with the flanges of each panel.

12. A modular building as claimed in claim 11, wherein caulking material is provided between each mating pair of an inner face flange and a panel flange.

13. A modular building as claimed in any preceding claim, wherein adjacent flanges of adjacent panels are secured together by mechanical fasteners.

14. A modular building as claimed in claim 13, wherein the mechanical fasteners pass through washers between the adjacent panels.

15. A modular building as claimed in any preceding claim, wherein adjacent flanges of adjacent panels are sealed together with caulking material.

16. A modular building as claimed in any one of claims 1 to 6, wherein at least some of the panels have transparent parts to their outer faces.

17. A method of erection of a modular building as claimed in claim 1, comprising the steps of connecting panels together at their adjacent, angled flanges to form one arch, connecting panels together to form another arch and connecting two arches together at adjacent, parallel flanges of the panels.

18. A method of erection as claimed in claim 17 of a modular building as claimed in claim 7, wherein the insulation is applied to the panels after at least one arch has been formed.

19. A method of erection as claimed in claim 18, wherein prior to the application of the insulation mechanical fasteners are employed to connect adjacent flanges close to their roots, these fasteners being covered by the insulation.

20. A method of erection as claimed in claim 18 or claim 19, wherein inner faces are added to cover the insulation after application of it.

21. A method of erection as claimed in claim 20, wherein mechanical fasteners are inserted through flanges of the panels and the inner faces to connect the panels after addition of the inner faces.

22. A modular building substantially as hereinbefore described with reference to Figures 1 to 3 or Figure 4 or Figure 5 or Figure 6 of the accompanying drawings.

23. A method of erection of a modular building substantially as hereinbefore described with reference to Figures 1 to 3 or Figure 4 or Figure 5 or Figure 6 of the accompanying drawings.

24. A panel for a modular building as claimed in any one of claims 1 to 16 or claim 22.