GB2452792A

GB2452792A - Method of cladding a temporary framework to create a shelter

Info

Publication number: GB2452792A
Application number: GB0806180A
Authority: GB
Inventors: Kenneth Macleod
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-04-05
Filing date: 2008-04-04
Publication date: 2009-03-18
Anticipated expiration: 2028-04-04
Also published as: GB0806180D0; GB0706667D0; GB2452792B

Abstract

A method of constructing a structure comprises erecting a framework 20 and cladding the framework with structural material 24 to form a structure (10, fig 1). The framework is then removed. The framework preferably includes panels 18 and window and door sections 22. The structural material may take the form of sacks of crushed rubble 26 layered in courses. A render may be applied to the structural material. The framework may include arched or domed roof formers. In other aspects, a fixing for spacing a skin away from a structure is provided. An alternative fixing for mounting an object to a structure is also provided. The structure formed takes advantage of rubble generated by disaster situations and results in a more permanent solution than conventional shelters.

Description

1 2452792 Improved Structure

Field of the Invention

The invention relates to a method of constructing a structure and particularly, but not exclusively to a method of constructing a dwelling.

Background to the Invention

Frequently situations arise where there is a requirement for shelters to be built quickly to accommodate large numbers of displaced people. These situations often * occur as the result of wars or as the result of a natural disaster such as a flood or a tsunami.

Conventional shelters have drawbacks; for example all the materials required to build the shelters generally have to be brought in to the area concerned, and as a result the erected structures are generally fairly lightweight and are temporary. These temporary shelters have to be replaced with permanent structures, a process which can * .* .. 15 take lengthy periods of time. * *e* * * *S*.

: Summary of the Invention

* According to a first aspect of the present invention there is provided a method * * S of constructing a structure, the method comprising the steps of: erecting a framework; cladding the framework with structural material to form a structure; and removing the framework.

In one embodiment, a structure built in accordance with the present invention is advantageous because removal of the framework permits the framework to be used repeatedly. This reduces the materials that need to be shipped to a location. A construction method which requires a reduced amount of material to be shipped to a location is advantageous in disaster recovery situations where a large number of homes or dwellings need to be erected.

Preferably, the step of removing the framework comprises removing the framework from within the structure.

Preferably, the structural material comprises sheaths.

Alternatively or additionally, the structural material comprises particulate matter.

Preferably, the particulate matter is rubble. In disaster situations, such as war or flood, there is often significant amounts of rubble generated. Furthermore using rubble facilitates the clearing of the disaster site and assists in returning the disaster site to normality. By "rubble" it is meant elements of construction material previously used to construct buildings, roads and the like.

Preferably, the rubble comprises crushed rubble. * **

Alternatively or additionally, the particulate matter comprises gravel, sand, **S.

aggregate, dried earth or the like. Any suitable, substantially non-shrinking material **S.

*..: may be used.

Most preferably, the structural material comprises sheaths filled with **** * * * particulate matter.

Preferably, the sheaths comprise a flexible material.

Preferably, the sheaths comprise a high strength material.

Preferably, the sheaths comprise a polymeric material.

Preferably, the sheaths are polypropylene. Alternatively the sheaths are nylon, canvas or any other suitable material. Polypropylene is preferred because of its high strength-to-weight ratio and good resistance to degradation.

Most preferably, the sheaths are a mesh material. In one embodiment the mesh material is polypropylene mesh. Mesh materials are lighter and therefore easier and cheaper to transport. Mesh materials also provide a surface to which a finishing material, such as render, can be applied, and meshes also permit the structure to "breathe", reducing the possibility of condensation building up.

The sheaths may be bags or sacks. Alternatively the sheaths may be tubes.

Preferably, the step of cladding the framework comprises layering the structural material. Layering the structural material, particularly if the structural material is in the form of tubes or bags of rubble makes for a robust completed structure.

Preferably, the structural material is layered in courses. Laying the structural material in courses, in the same way that bricks overlap in a wall, increases the rigidity of the structure.

Preferably, the method further includes the step of applying at least one *::. 15 finishing layer to the structure. The finishing layer may be provided to provide one or **S.

more of weather resistance, insulation or strength to the structure.

The finishing layer may be provided externally and/or internally to the structure. S...

The finishing layer may be render, harling, plaster, lime plaster or the like.

Preferably, the method further includes the step of applying a render to the structural material.

The render may be applied directly to the structural material.

Preferably, the method includes the further step of attaching a layer support surface to the structural material. A layer support surface may be provided to support a finishing layer to the structure.

Preferably, the layer support surface is attached to an external surface of the structural material.

Preferably, the layer support surface and the structural material define a void therebetween.

Most preferably, the layer support surface is spaced away from the structural material. Spacing the layer support surface away from the structural material to define a void allows for an insulating volume of air to reside between the support surface and the structural material.

Preferably, the method further includes the step of locating a breather membrane between the structural material and the layer support surface. The breather membrane may be adapted to permit air andlor water to travel through the membrane in only one direction. The breather membrane may be an insulating vapour control layer. The insulating vapour control layer may be Foil-Tec Double TM or Breather-Foil FRTM.

*::. 15 Preferably, the layer support surface is a mesh. A mesh provides a key for a * S..

finishing coat to adhere to. *S**

: Preferably, the mesh is a rigid mesh.

Preferably, the mesh is a metal mesh. The metal mesh may be steel, stainless **.

:::; steel, galvanised steel or any suitable mesh.

Preferably, the layer support surface is spaced away from the structural material by means of spacers.

Preferably, the spacers comprise an insulating material. An insulating material prevents cold bridging, that is prevents the transfer of warmth or cold across the void via the spacers.

Preferably, the spacers are nylon.

Preferably, the spacers are adapted to ventilate the space between the structural material and the layer support surface.

Preferably, the spacers include a tubular portion.

Preferably, the tubular portion permits the space between the structural material and the layer support surface to be ventilated.

Preferably, the spacers fix the layer support surface with respect to the structural material.

In one embodiment, the structural material comprises a mesh sheath which provides a key for the render.

I

Preferably, the framework comprises a frame.

Preferably, the frame comprises a plurality of frame members.

Preferably, the plurality of frame members are releasably attachable to each other.

Preferably, at least some of the plurality of frame members are releasably attachable to each other by means of pins. The pins may be mining pins. * I..

Alternatively or additionally, the frame members are releasably attachable by SI..

means of nuts and bolts. Any suitable attachment means may be used.

SI Preferably, the plurality of frame members are directly attachable to each S... * SI

* other. S. 5 * *.

Alternatively or additionally, the plurality of frame members are attachable to each other by means of connectors. The connectors may be cleats, such as angle cleats.

Preferably, the frame comprises a plurality of metal frame members.

Preferably, the metal members comprise steel members. Steel is particularly suitable material for the frame due to its high strength to weight ratio. Alternatively, galvanised steel or aluminium may be used.

Preferably, the frame comprises a plurality of hollow section members.

Hollow section members are lighter to transport than solid members.

The hollow section members may be box section members.

Preferably, the framework comprises a plurality of in-fill panels.

Preferably, the step of erecting the framework includes the at least partially in-tilling a frame with a plurality of in-fill panels. In-filling the frame provides a framework with a substantially continuous surface against which to align the structural material.

The in-fill panels may be metal, such as galvanised steel.

Alternatively or additionally, the framework further comprises at least one window section.

*:*::* 15 Preferably, the/each window section is adapted to create an opening for *SS. * *

**** . receiving a window frame **S.

Preferably, the/each window section is mountable to or within the frame.

Preferably, the/each window section comprises a head portion. The head S...

:::,; portion may be a lintel.

Preferably, the/each window section comprises an arched portion.

Preferably, the head portion comprises an arched portion.

Preferably, a portion of the/each window section extends outwardly from the frame.

Preferably, the extending portion is the head portion.

In one embodiment the window section has an arched lintel which extends outwardly from the frame. Providing an arched lintel permits the structural material to be laid in an arch shape over the lintel. The structural material can then be arranged such that the structural material remains in the arch shape when the window section is removed.

Preferably, the/each window section comprises a composite.

Alternatively, the/each window section comprises sheet or pressed metal.

Preferably, the/each window section comprises glass fibre composite.

Preferably, the/each window section is pre-formed.

Alternatively or additionally, the framework further comprises at least one door section.

Preferably, the/each door section is adapted to create an opening for receiving a door frame Preferably, the/each door section is mountable to or within the frame.

Preferably, the/each door section comprises a head portion. The head portion * *** * * may be a lintel. **S.

: Preferably, the/each door section comprises an arched portion.

Preferably, the head portion comprises an arched portion. ****

Preferably, a portion of the/each door section extends outwardly from the frame.

Preferably, the extending portion is the head portion.

In one embodiment the door section has an arched lintel which extends outwardly from the frame. Providing an arched lintel permits the structural material to be laid in an arch shape over the lintel. The structural material can then be arranged such that the structural material remains in the arch shape when the door section is removed.

Preferably, the/each door section comprises a composite.

Preferably, the/each door section comprises glass fibre composite.

Alternatively, the/each door section comprises pressed metal.

Preferably, the/each door section is pre-formed.

Preferably, the framework is erected such that, at least a portion of the framework define walls which taper towards each other.

Preferably, an upper portion of the framework defines walls which taper towards each other.

Preferably, the taper is approximately 200 to the vertical.

Preferably, the framework is arranged to such that, once clad, the structural material defines an arch over the top of the framework. This arrangement provides a roof for the structure which is self supporting. * S.

". 15 Alternatively or additionally, the framework comprises arcuate roof members. S... * * *S.S

Preferably, the roof members are adapted to span an opening defined by an *S** upper edge of the framework walls. S.

Preferably, the framework further comprises at least one roof member overlay. **S.

Preferably, the/each roof member overlay is adapted to define a roof former.

Preferably, the roof former is arched or domed. The structural material can be arranged against the overlays such that the structural material remains in the arch shape when the roof members and the overlays are removed.

Preferably, the/each roof member overlay comprises a composite.

Alternatively, the/each roof member overlay comprises sheet or pressed metal.

Preferably, the/each roof member overlay comprises glass fibre composite.

Preferably, the/each roof member overlay is pre-formed.

According to a second aspect of the present invention there is provided a method of constructing a plurality of structures, the method comprising the steps of: erecting a framework in a first location; cladding the framework with structural material to form a first structure; removing the framework; erecting the framework in a second location; cladding the framework with structural material to form a second structure; * and removing the framework.

According to a third aspect of the present invention there is provided a fixing for spacing a skin away from a structure, the fixing comprising: a tubular portion, in use, in fluid communication with a void defined between the protective coating support and the structure.

*:. 15 Preferably, the fixing further comprises at least one flat portion for inserting *...

between structural units from which the structure is made to secure the fixing to the structure.

Preferably the fixing further comprises a spacer having a width such that, in use, the width of the spacer determines the width of a void defined between the protective coating support and the structure.

According to a fourth aspect of the present invention there is provided a fixing for mounting an object to a structure, the fixing comprising: a threaded portion adapted to be engaged with the object to be mounted, and at least one flat portion for inserting between structural units from which the structure is made to secure the fixing to the structure.

It will be understood that preferred or other features of the first aspect may also be applicable to the second, third or fourth aspects and have not been repeated for brevity.

Brief Description of the Drawings

An embodiment of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 is a perspective view of a structure, generally indicated by reference numeral 10, built according to a first embodiment of the present invention; Figure 2 is a perspective of a framework used in the construction of the structure of Figure 1; Figure 3 is a perspective view of the bottom and middle sections of the frame; Figure 4 is a perspective view of part of the top section of the frame showing roof members; *..S * . *S.. . . . Figure 5 is a perspective view of the in-filled frame; Figure 6 is a perspective view of an in-fill panel; w.

Figure 7 is a perspective, section view of a structural material unit; Figure 8 is a perspective view of the framework top section showing roof formers; Figure 9 is a cross-section through part of the structure including the finishing layer; Figure 10 is a plan view of the fixing of Figure 9; and Figure 11 is a plan view of a further fixing for use in the structure of Figure 1.

Detailed Description of the Drawings

Figure 1 shows a perspective view of a structure, generally indicated by reference numeral 10, built according to a first embodiment of the present invention.

The structure 10 is a two-storey construction which includes windows 12 and doors 14.

The structure 10 is built according to a method which will be briefly described with reference to Figure 2 and then described in more detail with reference to Figures 3 to 10. Referring to Figure 2, a perspective of a framework 20 used in the construction of the structure of Figure 1, the method comprises firstly erecting a framework 20. The framework 20 comprises a frame 16 in-filled with a plurality of in-fill panels 18. Glass fibre composite door sections 22 are then fitted to the frame along with window and roof sections (not shown but discussed in due course).

Structural material 24 in the form of a plurality of structural material units 26, are then layered against the framework 20. The structural material units 26 are tamped and * .* .. 15 vibrated into place and once the framework 20 is fully clad the frame 16, in-fill panels * S. *. 18, door sections 22, window sections and roof sections can all be removed leaving the structural material 24 in place.

The components of the structure 10 will now be described in more detail. *S..

References is firstly made to Figure 3, a perspective view of the bottom 30 and middle * 20 32 sections of the frame 16. As can be seen the frame 16 comprises a plurality of frame members 28. The frame members 28 are releasably connected to each other using pins and brackets. The frame 16 is initially erected vertically at the bottom section 30 of the frame 16 and then with an inward taper at the middle section 32 of the frame 16. As can be seen from Figure 3 at the top of the tapered section 32 an opening 34 is defined by the frame 16. This opening 34 is then spanned by arcuate roof members 36 which can be seen on Figure 4, a perspective view of part of the top section 38 of the frame 16.

Referring now to Figure 5, a perspective view of the in-filled frame 16, the frame 16 is then in-filled with a plurality of in-fill panels 18. Openings 40 are left to receive the door sections 22 (Figure 2) and similar openings are left for windows sections (not shown).

The in-fill panels 18 are manufactured from folded pressed metal panels. The in-fill panels 18 can be seen most clearly in Figure 6, a perspective view of an in-fill panel 18.

The in-fill panels 18 comprise frame engaging surfaces 42 which engage and fit snugly with the frame members 28.

The structural material units 26 are then layered around the structure. From Figure 7, a perspective, section view of a structural material unit 26, it can be seen that each unit 26 comprises a polypropylene mesh 44 filled with crushed rubble 46. * s*

* 15 Rubble 46 is in plentiful supply in disaster recovery situations, for example, in the * 0S * * * aftermath of a war, and if required the rubble 46 can be crushed on site.

Referring back to Figure 2, the structural material units 26 are built up in layers around the structure, with openings being left for the doors 14 and windows 12.

* : The structural material 24 abuts the sides 48 of each door section 22 and are laid over ** S 5: 20 an arcuate head portion 50 to form a self supporting arch which remains in place when the framework 20, including each door section 22, is dismantled. Removal of each door section 22 leaves an aperture defined by the structural material 24 into which a door 14 and door frame can be inserted. The window sections (not shown) are of similar construction and work in a similar way.

The structural material units 26 are laid up the vertical framework section 30 and then up the tapered middle section 32. Referring to Figure 8, a perspective view of the framework top section 38 during construction, the arcuate roof members (not visible) are overlaid with a number of glass fibre composite roof formers 52. The structural material units 26 are built up the side of the tapered framework section 32 and then laid over the top of the roof formers 52 to form a self supporting arched roof.

Once the framework 20 is fully clad with structural material 24, the framework including the frame 16, the in-fill panels 18, the door sections 22, the window sections the roof members 36 and the roof formers 52 are all removed for re-use at another location.

Windows 12 and doors 14 can be inserted in the openings 40 and the structure can be finished with a finishing layer 60 as shown in Figure 1.

* *. Reference is made to Figure 9, a cross-section through part of the structure 10 * * * * *.

** including the finishing layer 60. The finishing layer 60 comprises a base coat of render 62 applied to the polypropylene mesh 44 of the structural material 24. The **..

* mesh 44 acts as a keyed surface against which the base render 62 can attach. An insulating breathable membrane 64 is laid over the base render 62 and on top of the *.: membrane 64 is laid a stainless steel mesh 66. The mesh 66 is spaced from the breather membrane 64 by a nylon spacer 68. The mesh 66 and spacer 68 are secured relative to the structural material 24 by a number of fixings 70.

Referring to Figure 10, a plan view of a fixing 70 for securing the mesh 66 to the structural material 24, each fixing 70 comprises a tubular threaded portion 72 and a pair or elongate flat members 74 for inserting between adjacent stacked structural material units 26. Threaded portion 72 is adapted to receive a nut 76 (Figure 9) which secures the steel mesh 66 and the nylon spacer 68 with respect to the structural material 24 through an angled, pressed metal washer 78. The provision of the nylon spacer 68 allows for an air gap 80 between the breather membrane 64 and the steel mesh 66. Slots 82 are provided in the sides of the tubular portion of the fixing 72 which are in communication with the tubular portion throughbore 84 which in turn allows the air gap 80 to vent to an external surface 86 of the structure 10, preventing a build up of condensation. The external surface 86 is provided with external render layer 88. Once the external render layer 88 has been applied and has set, the exposed part 90 of the fixing 70 can be removed to allow for a flush finish. The fixing 70 is made of nylon to prevent cold bridging across the air gap 80.

Figure 11 shows a plan view of a further fixing 91 for use in the structure 10 of Figure 1. The further fixing 90 can be used to attached, for example, wall runners (not shown) to an internal surface of the structure 10. The fixing 90 comprises a * ** length of mild steel bar 92 which defines a thread 94. Extending from the end of the * S I * bar 92 are two elongate flat members 96. Similar to the flat members 74 of the fixing * of Figures 9 and 10, the flat members 96 are adapted to be trapped between course of S...

:. the structural material 24. Once trapped, an object, such as a wall runner or a beam, can be engaged with the threaded bar 92 and secured with a nut (not shown) Various modifications and improvements may be made to the above described embodiment without departing from the scope of the invention. For example, the finishing coat 60 may only comprises a base coat or render 60 or a coat of another material such as mud. Furthermore, although not described, further improvements could be made to the structure 10 such as the inclusion of an internal stairwell and an internal floor at first floor level.

In alternative embodiments, only one layer of render is applied to the structure.

This layer could be one of the base layer or the external layer.

Claims

1. A method of constructing a structure, the method comprising the steps of: erecting a framework; cladding the framework with structural material to form a structure; and removing the framework.

2. The method of claim 1, wherein the step of removing the framework comprises removing the framework from within the structure.

3. The method of either of claims 1 or 2, wherein the structural material comprises sheaths.

*

4. The method of any preceding claim, wherein the structural material comprises particulate matter. * S.. *S*,

S

*

5. The method of claim 4, wherein the particulate matter is rubble. SI.

S *...

S

*

6. The method of any preceding claim, wherein the structural material comprises sheaths filled with particulate matter.

7. The method of claim 3, wherein the sheath comprises a flexible material.

8. The method of either of claims 3 or 7, wherein the sheaths comprise a high strength material.

9. The method of any of claims 3, 7 or 8, wherein the sheaths comprise a polymeric material.

10. The method of any of claims 3, 7, 8 or 9, wherein the sheaths are a mesh material.

11. The method of any of claims 3 or 7 -10, wherein the sheaths are bags or sacks.

12. The method of any of claims 3 or 7-10, wherein the sheaths are tubes.

13. The method of any preceding claim, wherein the step of cladding the framework comprises layering the structural material. S... *S*.

14. The method of claim 13, wherein the structural material is layered in courses.

S 55.

S *..

15. The method of any preceding claim, wherein the method further includes the *5*.

step of applying at least one finishing layer to the structure.

16. The method of claim 15, wherein the/each finishing layer is provided externally and/or internally to the structure.

17. The method of either of claims 15 or 16, wherein the method further includes the step of applying a render to the structural material.

18. The method of any preceding claim, wherein the method includes the further step of attaching a layer support surface to the structural material.

19. The method of claim 18, wherein the layer support surface is spaced away from the structural material.

20. The method of either of claims 18 or 19, wherein the method further includes the step of locating a breather membrane between the structural material and the layer support surface. OlO

21. The method of claim 20, wherein the breather membrane is an insulating vapour control layer. * *. * S * * S.

22. The method of any of claims 18-21, wherein the layer support surface is a *SS. mesh. *S*. *S*. S*S

S

* :

23. The method of any of claims 18 -22, wherein the layer support surface is spaced away from the structural material by means of spacers.

24. The method of claim 23, wherein the spacers comprise an insulating material.

25. The method of either of claims 23 or 24, wherein the spacers are adapted to ventilate the space between the structural material and the layer support surface.

26. The method of any of claims 23 to 25, wherein the spacers include a tubular portion.

27. The method of claim 26, wherein the tubular portion permits the space between the structural material and the layer support surface to be ventilated.

28. The method of any of claims 23 to 27, wherein the spacers fix the layer support surface with respect to the structural material.

29. The method of any preceding claim, wherein the framework comprises a frame.

30. The method of claim 29, wherein the frame comprises a plurality of frame * S. * S S * .5 members. *SS. *S..

S

*

31. The method of claim 30, wherein the plurality of frame members are 5.

S

releasably attachable to each other.

S S. *

S

32. The method of either of claims 30 or 31, wherein the plurality of frame members are directly attachable to each other.

33. The method of any of claims 30 to32,wherein the plurality of frame members are attachable to each other by means of connectors.

34. The method of any of claims 29 to 33, wherein the framework comprises a plurality of in-fill panels.

35. The method of claim 34, wherein the step of erecting the framework includes the at least partially in-filling a frame with a plurality of in-fill panels.

36. The method of any of claims 29 to 35, wherein the framework further comprises at least one window section.

37. The method of claim 36, wherein the/each window section is mountable to or within a frame.

38. The method of either of claims 36 or 37, wherein the/each window section *:.:: comprises a head portion. *Se. *S*. * **S.

*

39. The method of any of claims 36 to 38, wherein the/each window section 4** comprises an arched portion. *.S. * * * **

40. The method of any of claims 36 to 39, wherein the/each window Section is pre-formed.

41. The method of any of claims 29 to 40. wherein the framework further comprises at least one door section.

42. The method of claim 41, wherein the/each door section is adapted to create an opening for receiving a door frame.

43. The method of either of claims 41 or 42, wherein the/each door section is mountable to or within the frame.

44. The method of any of claims 41 to 43, wherein the/each door section comprises a head portion.

45. The method of any of claims 41 to 44, wherein the/each door section comprises an arched portion.

46. The method of any of claims 41 to 45, wherein the/each door Section is pre-formed. *S..

S S...

*

47. The method of any of claims 29 to 46, wherein the framework is erected such that, at least a portion of the framework define walls which taper towards each other. * S.

S *

S * S S * **

48. The method of any of claims 29 to 47, wherein the framework comprises arcuate roof members.

49. The method of claim 48, wherein the framework further comprises at least one roof member overlay.

50. The method of claim 49, wherein the/each roof member overlay is adapted to define a roof former.

51. The method of claim 50, wherein the roof former is arched or domed.

52. A method of constructing a plurality of structures, the method comprising the steps of: erecting a framework in a first location; removing the framework; erecting the framework in a second location; cladding the framework with structural material to form a second structure; and removing the framework. * *. * * . * *. * * **.*

53. A fixing for spacing a skin away from a structure, the fixing comprising: **** a tubular portion, in use, in fluid communication with a void defined between the protective coating support and the structure.

54. The fixing of claim 53, wherein the fixing further comprises at least one flat portion for inserting between structural units from which the structure is made to secure the fixing to the structure.

55. The fixing of either of claims 53 or 54, wherein the fixing further comprises a spacer having a width such that, in use, the width of the spacer determines the width of a void defined between the protective coating support and the structure.

56. A fixing for mounting an object to a structure, the fixing comprising: a threaded portion adapted to be engaged with the object to be mounted; and at least one flat portion for inserting between structural units from which the structure is made to secure the fixing to the structure. Sb * .* * S * * * *S*. * * **S. **** * I... * * S...

S S.

S S S * **