GB2456535A

GB2456535A - A floor structure in or for a building unit

Info

Publication number: GB2456535A
Application number: GB0800787A
Authority: GB
Inventors: Glyn Thomas Boddy
Original assignee: Portakabin Ltd
Current assignee: Portakabin Ltd
Priority date: 2008-01-17
Filing date: 2008-01-17
Publication date: 2009-07-22
Also published as: GB0800787D0

Abstract

The invention relates to a building unit (10 figure 4) including a floor structure comprising a layer of settable material 30. The building unit may be a portable prefabricated building unit. A plurality of support members 20 are positioned underneath the layer of settable material which may be concrete, a resin-like material or a plastics material. The support members are preferably metallic sheets with a plurality of elongate recesses 19 which receive the concrete. The recesses may be trapezoidal shaped such that the side walls 20a, 20b extend towards each other as they extend towards an upper surface 31 of the concrete. The support members may be positioned on a support frame (12, 14 figure 2) such that the edges of the support members overlap. A later embodiment relates to a method of manufacturing a building unit comprising said floor.

Description

2456535

Title: A building unit

5 Description of Invention

This invention relates to a building unit. The building unit is preferably a portable, prefabricated, building unit which is factory assembled for delivery to a prepared site in assembled condition. Alternatively, the building unit may be 10 provided as a kit of parts for assembly at a desired location. More particularly, this invention relates to a floor structure of a building unit.

EP 0058354, EP 0104406 and GB 2084213 each disclose an example of such a portable building unit which may be intended to occupy a site, permanently 15 or to occupy the site temporarily and then be transported to a further site.

GB 2311794 discloses a conventional floor structure for a portable building unit. The floor structure comprises a pair of side beams connected together in spaced relationship by transversely extending joists (a pair of spaced apart 20 end joists and a plurality of intermediate joists disposed between said end joists), a floor panel supported on the floor frame, and an underdrawing spaced from the floor frame and disposed beneath the joists.

Portable building units are often positioned one on top of another, e.g. two or 25 more units may be positioned on top of each other, and/or linked side by side to provide a multi-level open plan building. In such configurations the floor structures of the building units, particularly, but not exclusively, the floor structure of second building unit and upwards (i.e. that of the third, forth etc. building unit) may exhibit vibration characteristics that limit the scope of 30 possible uses for those floors e.g. a high "vibration response factor". It is generally desired for a floor of a building unit to have as low a "vibration

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response factor" as possible, depending on the environment in which the building unit is to be used.

It is therefore an object of the invention to provide a building unit having a floor 5 structure which exhibits improved vibration characteristics particularly, but not exclusively, when used in multi-storey configurations.

According to a first aspect of the invention we provide a building unit including a floor structure comprising a layer of settable material.

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Further features of the first aspect of the invention are set out in claims 2 to 18 appended hereto.

According to a second aspect of the invention we provide a method of 15 manufacturing a building unit, comprising the steps of:-providing a floor structure support member;

applying a settable material onto an upper surface of the support member;

permitting the settable material to set.

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Further features of the second aspect of the invention are set out in claims 19 to 27 appended hereto.

Examples of the invention will now be described by way of example only with 25 reference to the accompanying drawings, of which:-

Figure 1 is a cross-sectional view of a floor structure in accordance with the present invention;

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Figure 2 is a perspective view of a section of a floor structure support frame;

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Figure 3 is a perspective view of a floor structure in accordance with the present invention shown partway through the manufacture thereof; and

Figure 4 is a further perspective view of a floor structure in accordance with 5 the present invention shown partway through the manufacture thereof.

Referring to figure 1 this shows a cross-sectional view of a manufactured floor structure of a building unit 10 in accordance with the present invention. The floor structure is supported on top of a conventional support frame (see figure 10 2) comprising outer frame parts 12 and intermediate frame parts 14. The floor structure includes a plurality of support members 20 (only one shown in figure 1) and a layer of settable material 30, which is this example is a cement or a cementitious material. Of course, it will be appreciated that the settable material could take many other forms, depending on the environment in which 15 the building unit is to be used, e.g. a resin or resin-like material or a plastics material.

Each support member 20 is in the form of a corrugated metallic sheet, e.g. galvanised steel, in that the sheet is formed such that it includes a plurality of 20 elongate recesses 19 which in this example are aligned substantially parallel with each other (see figure 3).

Each recess 19 includes a pair of opposing side walls 20a, 20b, which extend towards each other as they extend towards an upper surface 31 of the layer of 25 cement 30. In other words, each recess is substantially trapezoidal in cross-section and thus provides a cavity to receive the cement 30. The shape of the recesses 19 provides for a strong connection between the cement layer 30 and the support member 20 once the cement has set/cured.

30 Manufacturing the floor structure is performed as follows. Firstly, a plurality of support members 20 are positioned on top of the support frame parts 12, 14.

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In this example there are twenty four support members 20 - four spanning the lengthwise direction of the building unit 10 and six spanning the width wise direction of the building unit 10. Of course, it must be appreciated that any number of support members 20 could be used. The support members 20 are 5 positioned such that the recesses 19 therein are aligned substantially parallel with a lengthwise direction of the building unit 10. Of course, it must be appreciated that the support members 20 could be aligned transversely to the lengthwise direction of the building unit 10.

10 The support members 20 are positioned such that end and side edge portions of each support member 20 overlap end and side edge portions of adjacent support members 20 (see arrow 28 in figure 3). This inhibits the flow of cement between the support members 20 when the cement is applied to the support members 20. A peripheral wall 25, e.g. in the form of a metal angle or 15 plate, the top edge of which aligns with the intended surface of the floor, is then connected to the outermost edges of the outermost support members 20, so as to block the open ends of the recesses 19, thus providing a series of lengthwise cavities to receive the cement 30.

20 Once positioned, the support members 20 are connected to the frame parts 12, 14 using conventional fasteners, such as rivets 29. Side 22 and end 21 walls of the building unit 10 can be connected to the frame parts 12 either before or after manufacture of the floor. As shown in figure 3, the floor is manufactured with two end walls 22 and one side wall 21 already connected to 25 the frame parts 12. In this example, the other side wall is not connected to the floor structure, because this building unit is intended to form an end part of a larger building. In other words, the building unit 10 is intended to be connected to another building unit having ends walls 22, but no side walls 21. The latter building unit is then connected either to another building unit having 30 only ends walls 22 or a building unit having end walls 22 and one side wall 21 (i.e. a mirror image of the building unit 10). Connecting all three, or more,

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building units together side by side provides a larger open plan building. The building unit 10 may be constructed with any number of walls, from none to four, depending on the configuration of the finished building in which the building unit is to be used.

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Cement 30 is then applied to the support members 20 and is distributed, e.g. by workmen 40 using conventional implements, to as to provide a substantially even upper surface 31. The upper surface 31 can then be prepared so as to provide an appropriate surface texture for the environment in which the 10 building unit is to be used. For example, a smooth upper surface may be required if no further floor layers are to be applied to the upper surface 31. A textured surface may be necessary if a further floor surface, e.g. ceramic floor tiles, is to be connected to the upper surface 31 using an adhesive.

15 It is generally desired for the floor of a building unit to have as low a "vibration response factor" as possible, depending on the environment in which the building unit is to be used. When two or more known building units are positioned on top of each other, the floor structure of second building unit and upwards has a higher "vibration response factor" than the floor of the first 20 building unit (often known as 'ground' building unit). This can lead to increased vibration transmission during use. However, it has been shown through experimentation that the floor structure in accordance with the present invention is advantageous over known floor structures in building units, e.g. portable, prefabricated, building units, because it provides improved floor 25 vibration characteristics, namely a lower "vibration response factor". This means that the building unit of the present invention can be used in a wider range of environments. For example, when two building units are positioned on top of each other the lower "vibration response factor" of the floor structure means that less vibration, caused by foot-fall or other sources, is transmitted 30 from its source through the floor to other parts of the floor or building. This is particularly important in, for example, buildings containing operating theatres

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or high precision monitoring instrumentation. In addition, less noise is heard in the lower building unit, e.g. noise made by persons walking across the floor of the upper building unit.

5 When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

10 The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse 15 forms thereof.

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Claims

1. A building unit including a floor structure comprising a layer of settable material.

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2. A building unit according to claim 1 including a support member which is positioned beneath the layer of settable material.

3. A building unit according to claim 2 including a plurality of support 10 members positioned adjacent each other beneath the layer of settable material.

4. A building unit according to claim 2 or claim 3 wherein a portion of each support member overlaps a portion of an adjacent support member.

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5. A building unit according to any preceding claim wherein the support member includes at least one recess to receive a portion of the settable material.

20 6. A building unit according to claim 5 wherein the or each recess in the support member is elongate and extends either width-wise or lengthwise of the floor structure.

7. A building unit according to claim 6 wherein longitudinal axes of the 25 elongate recesses are aligned substantially parallel with each other.

8. A building unit according to any one of claims 5 to 7 wherein each recess includes a pair of opposing side walls.

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9. A building unit according to claim 8 wherein the opposing side walls of each recess extend towards each other as they extend towards an upper surface of the layer of settable material.

5 10. A building unit according to any one of claims 5 to 9 wherein each recess is substantially trapezoidal in cross-section.

11. A building unit according to any one of claims 2 to 10 including a peripheral wall which, together with the support member(s) provides a cavity to

10 receive the settable material.

12. A building unit according to any preceding claim wherein each support member is metallic.

15 13. A building unit according to any preceding claim wherein the settable material is an uppermost layer of the floor structure.

14. A building unit according to any preceding claim wherein the settable material comprises cement or a cementitious material.

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15. A building unit according to any one of claims 1 to 13 wherein the settable material comprises a resin or resin-like material.

16. A building unit according to any one of claims 1 to 13 wherein the 25 settable material comprises a plastics material.

17. A building unit comprising a plurality of walls and a roof, and a floor structure according to any one of claims 1 to 16.

30 18. A portable, prefabricated, building unit comprising a plurality of walls and a roof, and a floor structure according to any one of claims 1 to 16.

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19. A method of manufacturing a building unit, comprising the steps of:-providing a floor structure support member;

applying a settable material onto an upper surface of the support 5 member;

permitting the settable material to set.

20. A method according to claim 19 wherein the settable material is in a liquid/semi-solid state and is poured onto the upper surface of the support

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21. A method according to claim 19 or claim 20 including providing two or more floor structure support members and positioning the floor structure support members adjacent each other before the settable material is applied

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22. A method according to claim 21 including positioning a portion of each support member such that it overlaps a portion of an adjacent support member.

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23. A method according to any one of claims 19 to claim 22 including connecting a peripheral wall to the support member(s) so as to provide a cavity to receive the settable material.

25 24. A method according to any one of claims 19 to 23 wherein the settable material comprises cement or a cementitious material.

25. A method according to any one of claims 19 to 23 wherein the settable material comprises a resin or resin-like material.

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26. A method according to any one of claims 19 to 23 wherein the settable material comprises a plastics material.

27. A method according to any one of claims 19 to 26 including distributing 5 the settable material over the support member(s) so as to provide a substantially even upper surface thereof.

28. A building unit substantially as hereinbefore described with reference to and/or as shown in the accompanying drawings.

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29. A method of manufacturing a building unit substantially as hereinbefore described with reference to and/or as shown in the accompanying drawings.

30. Any novel feature or novel combination of features described herein 15 with reference to and/or as shown in the accompanying drawings.