GB2472761A - System for constructing buildings from converted steel containers - Google Patents
System for constructing buildings from converted steel containers Download PDFInfo
- Publication number
- GB2472761A GB2472761A GB0908086A GB0908086A GB2472761A GB 2472761 A GB2472761 A GB 2472761A GB 0908086 A GB0908086 A GB 0908086A GB 0908086 A GB0908086 A GB 0908086A GB 2472761 A GB2472761 A GB 2472761A
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- GB
- United Kingdom
- Prior art keywords
- fixing
- adhesive
- building
- self
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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- 239000010959 steel Substances 0.000 title claims abstract description 18
- 238000009432 framing Methods 0.000 claims abstract description 41
- 239000000853 adhesive Substances 0.000 claims abstract description 39
- 239000006260 foam Substances 0.000 claims abstract description 36
- 230000001070 adhesive effect Effects 0.000 claims abstract description 18
- 239000007921 spray Substances 0.000 claims abstract description 16
- 229910052751 metal Inorganic materials 0.000 claims abstract description 15
- 239000002184 metal Substances 0.000 claims abstract description 15
- 230000005494 condensation Effects 0.000 claims abstract description 5
- 238000009833 condensation Methods 0.000 claims abstract description 5
- 238000009413 insulation Methods 0.000 claims description 44
- 238000000034 method Methods 0.000 claims description 31
- 230000008569 process Effects 0.000 claims description 22
- 238000010276 construction Methods 0.000 claims description 12
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 11
- 239000011496 polyurethane foam Substances 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- 238000000926 separation method Methods 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 7
- 230000004888 barrier function Effects 0.000 claims description 4
- 239000004566 building material Substances 0.000 claims description 4
- 230000001627 detrimental effect Effects 0.000 claims description 3
- 230000007613 environmental effect Effects 0.000 claims description 3
- 239000011493 spray foam Substances 0.000 claims 8
- 230000005540 biological transmission Effects 0.000 claims 4
- 238000005538 encapsulation Methods 0.000 claims 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims 3
- 230000032683 aging Effects 0.000 claims 2
- 230000001681 protective effect Effects 0.000 claims 2
- 230000001413 cellular effect Effects 0.000 claims 1
- 239000006261 foam material Substances 0.000 claims 1
- 239000004814 polyurethane Substances 0.000 abstract description 16
- 229920002635 polyurethane Polymers 0.000 abstract description 13
- 238000012546 transfer Methods 0.000 abstract description 3
- 238000013461 design Methods 0.000 description 10
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- 239000000835 fiber Substances 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B1/34815—Elements not integrated in a skeleton
- E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7675—Insulating linings for the interior face of exterior walls
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B2001/7691—Heat reflecting layers or coatings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H1/00—Buildings or groups of buildings for dwelling or office purposes; General layout, e.g. modular co-ordination or staggered storeys
- E04H1/12—Small buildings or other erections for limited occupation, erected in the open air or arranged in buildings, e.g. kiosks, waiting shelters for bus stops or for filling stations, roofs for railway platforms, watchmen's huts or dressing cubicles
- E04H2001/1283—Small buildings of the ISO containers type
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Building Environments (AREA)
Abstract
The system comprises fixing devices and framing apparatus to convert steel containers, such as ISO shipping containers, into buildings. The system may include top stud fixing brackets 1, wall stud 4, fixing brackets 2 and ceiling joists 8, secured to the walls of the container by fixings 1, 2, 3. The fixing and framing apparatus may be thermally and acoustically insulated from the metal walls of the container. Also claimed is a self adhesive foam fixing pad which may include a disposable peel off tape to keep adhesion prior to use. Also claimed is a building system where spray applied polyurethane is used to cover components within the container in order to, for example, reduce heat transfer and condensation. The system may come in the form of a kit.
Description
The following is a provisional explanation and description of the invention
Introductory Statement of Invention
This invention relates to the inventive device, apparatus, method and process used to build or convert steel shell structures suitable for the purposes of producing habitable buildings. For example converting standard or non-standard ISO steel shipping containers into habitable buildings. The device, apparatus and methodology of process employed improves the process of conversion and the functionality and performance of the finished product.
Introduction and background
ISO intermodal shipping containers are purpose made to transport goods by road, rail, sea and air. They can also be taken out of the transport arena and converted for use as prefabricated modular buildings.
When converted for use as office, living or other types of habitable use, the converted containers must comply with appropriate building legislation and codes of practice, typically this would include building regulations, statutory health and safety requirements, and other statutory performance standards.
Complying with the various regulatory requirements can be very difficult to achieve using traditional or standard building techniques because of the originating size, typology and material composition of shipping containers. In particular there are demanding requirements associated with meeting the Building Regulations 2000 and as updated, particularly Part L, relating to conservation of fuel and power, which requires that completed buildings are sufficiently well insulated to meet and preferably exceed governing heat-loss and energy efficiency standards.
There are also other problems that can be encountered related to how new interior or exterior linings can be fixed to the steelwork without penetrating and thereby compromising the watertightness and airtightness of the steel enclosure, and how the integrity and effectiveness of the linings and thermal and acoustic insulation can be achieved and maintained.
Typical problems encountered in the conversion of shipping containers include; Wall and roof conversion constructions can have excessive bulk and thickness, resulting in a diminution of the available interior head height and useable floor space. Cold-bridging can occur when interior fixings or building materials are in close proximity to, or in contact with the external metalwork of the container resulting in excessive localized heat loss or gain. Traditional techniques can lead to constructions that are inflexible and difficult to adapt. Condensation can occur on concealed or exposed interior metalwork, leading to rusting, dampness and mould growth, which reduces the useful life span of the building. Mechanical fixings can puncture the original metal skin of the container resulting in sub-standard weatherproofing and airtightness. A reduction in acoustic attenuation performance can occur when interior or exterior fixings or building materials are in direct contact with or in very close proximity to the external metalwork of the container. Excessive dust and noise can be generated while working in the restricted metal enclosure, leading to health and safety compliance requirements. Welding, cutting and drilling and other heat generating processes can lead to increased fire risk and health and safety compliance requirements, together with additional insured risk premiums. Traditional nail, screw and bolt type mechanical fixings can cause difficulties when assembling, modifying or disassembling the framing and lining materials used in the conversion construction process.
Because of the high coefficient of heat transfer of steel, the phenomenon of cold bridging via structure, fixings or fixtures, can have a particularly detrimental effect on heat gain/loss, which makes compliance with the regulations much more difficult to achieve. This in turn makes the ability to eliminate or significantly reduce cold-bridging a very desirable feature.
Statement of Invention and Advantages
To mitigate these and other associated problems that can be encountered before, during and after the conversion process, the invention features a series of integrated devices and processes which provide a sequential and seamlessly coordinated building system, bringing together standard commercially available components with new and inventive components in an innovative and novel way. The system makes available a new and transformational product by process.
The invention makes the whole process of procurement and construction more efficient by unifying, rationalizing and integrating the components and the process of assembly.
Desirable enhancements include; Reduced number of materials and components required.
Constituting a stable of readily available cost-effective components. Cost-effective purchasing and storage. Setting-out procedures made quicker and more accurate.
Simplification of assembly and construction process. Standardized and fewer components required. Sequencing and process of building easier to understand and quicker to learn.
Facilitates rapid and accurate assembly. Modifications and adaptations are easily achieved at all stages of the building process. Material wastage is reduced. A smaller carbon footprint' is made more achievable. The system is extremely flexible and adaptable to design changes, allowing for various building interventions, services, typologies, insulation, fabrics, linings and layouts to be incorporated throughout the building programme.
By way of example, interior linings and board finishing can be flush finished plasterboard, through to demountable board linings with removable cover strips fixed onto the same framing system. When used in conjunction with exterior insulation and cladding, the system brings with it more benefits, with additional improvements to all of the performance and design criteria in a similar way.
The system utilizes industry standard building components -linings and metal framing systems, enabling them to be rapidly and securely fixed, whilst retaining thermal, acoustic and hermetic separation from the metalwork of the shipping container, thus guaranteeing the environmental integrity and performance of the finished product. All of the components are based upon a stable of commercial products that are readily available both nationally and internationally.
The choice and use of lightweight pressed metal framing sections and components is desirable because it avoids the vagaries, inconsistencies and defects normally associated with standard readily available commercial timber products which may otherwise be used in similar building and conversion work.
The particular components used, and the manner in which they are assembled ensure minimal surface contact area between connecting components which in turn reduces yet further the capacity for heat transfer and cold bridging across the building fabric from outside to inside.
The system utilizes the magnetic properties of both the steel container and the selected metal framing components, so that holding magnets can be used for the positioning and hands-free holding in place of work prior to fixing.
The flexibility of the system allows for containers to be joined together, openings for windows, doors, services and the like to be formed and trimmed using the standard stable of system components, sequence and processes.
Fixings are also fixed in place using localized application of polyurethane instant fixative to mitigate cold-bridging.
The whole assembly, together with all exposed interior surfaces of the container subject to external temperature conditions are encapsulated within a layer of spray applied polyurethane insulation.
The spray applied insulation is fully conformable to the shape of the recipient surface and is dispensed to partially or fully embed the metal framing brackets as required to affix them to the inside of the container.
The space established by the adhesive fixing pad placed earlier between the container metalwork and the framing bracket is first filled around and then encapsulated with insulation, ensuring a thermal, acoustic and hermetic barrier across each and every joint between the external metalwork of the container and the interior construction.
The inside walls and roof of each container is encapsulated with with non-vapour permeable spray applied polyurethane insulation ensuring that there is no condensation and virtually no cold-bridging and a monocoque air-tight construction.
The foam can be applied in varying thicknesses, to suit various design and performance criteria. This benefits the product by facilitating extended life-cycle adaptation to the imposition ofenergy conservation legislation over time.
The unique two-stage process, allows for fast and fully adjustable setting-out of the entire secondary framing system prior to fixing and encasement with spray applied polyurethane insulation, ensuring virtually no cold-bridging and effecting a monocoque air-tight construction.
A composite quilt of rockwoollmineral fibre/silver reflective foil/spacetherm or similar insulation material is then incorporated within the Wall/ceiling/floor linings to suit requisite design criteria.
Typically the underside of the floor of the container would be sprayed from underneath with polyurethane insulation to the full depth of the floor joists to create a very well insulated floor construction. Additional insulation may be incorporated on the inside of the floor together with the interior floor finish.
The quilt and lining material provide the requisite fire and smoke resistance to the interior of the building. The modular nature of the building acts as useful fire and smoke compartmentation and helps towards meeting fire regulations.
Typically the finished building will be extremely well insulated and have a very airtight construction, requiring very little heating or cooling to achieve comfort conditions.
Marking and Setting-out Marking and setting-out of the inside and outside of the container is made by marker pen following measurement by tape measure, plumb-bob, spirit level, standards, laser equipment and the like, in accordance with design information and layout requirements.
Initial Setting-out and Placement of Fixings Setting-out, alignment and placement of first-fix metal brackets, fixings and framing elements on any and all steel surfaces is by extensive use of standard and purpose made work holding magnets. This achieves a fast, accurate and replicable process. The magnets are re-usable time and time again and components can be easily nudged into position or repositioned as needed. The magnets hold the components firmly in place in hands-free mode until such time as they are ready for permanent fixing, at which time the magnets can be removed for re-use.
Setting-out, alignment and placement of first-fix self-adhesive insulating fixing pads, together with first-fix brackets is carried out during this phase of the works programme.
In some instances one side of the fixing pad is first affixed to the bracket or framing component. The fixing pad protection can then be peeled off the opposing face, ready for the primed framing component to be instantly press fixed into the required position.
Once stuck-on, the self-adhesive fast-fix pads and brackets are capable of receiving and supporting the push-on clip-fix framing, which can be assembled, disassembled and modified as required, until complete. The foam fixing pads guarantee that both the bracket itself and the framing is securely fixed to, but separated from the metalwork of the container.
The unique two-stage process, allows for fast, fully adjustable setting-out of the entire secondary framing system prior to permanent fixing and encasement with spray applied polyurethane insulation in the follow-on building works sequence.
The System and Fixings The individual foam fixing pads are made available in varying thicknesses, enabling the fixing brackets and framing to be separated from the container metalwork by varying degrees to suit differing design and performance criteria. This is desirable to avoid cold-bridging and to ensure that the product has extended life-cycle development capability to adapt to the imposition of more demanding energy conservation legislation over time.
The adhesive foam fixing pads provide a structural, thermal and acoustic barrier joint.
Achieving a thermal and acoustic isolating joint to provide positional and structural fixing of interior metal framing and lining to the primary structural metal envelope to prevent cold and hot bridging and to enhance acoustic separation between building elements.
The top stud fixing typically comprises an assembly of Lafarge Dryliner fittings; RD7 with structural self-adhesive foam fixing pad affixed.
Variants of the stud fixing include a back-to-back variant, typically comprising an assembly of Lafarge Dryliner fittings; 2no. RD7's placed back-to-back with an M6x12 set screw joining the two together.
A further variant of the stud fixing includes a spacer type, typically comprising an assembly of Lafarge Dryliner fittings; 2no. RD7's placed back-to-back with an M6 set screw or studding to joining the two brackets securely together at a set distance apart.
Typically, the fast fixing pads comprise of pressure-sensitive, high-strength, high-tack self-adhesive, acrylic foam tape/pads with peel-off protection, affixed either side of a closed cell rigid pvc insulating spacer board. Each pad is sized to suit the component being fixed, typically 25mm x 50mm x 8mm for the standard unit size. The pads are simply firmly pressed into contact with the container metalwork in the requisite position with adhesive side exposed.
As they are pressure sensitive the fixing pads readily and positively adhere to the surface of the container. Exhibiting conformable adhesive surface skins, the fixing pads readily compensate for any surface defects or imperfections on the receiving surface.
Where necessary surfaces are prepared prior to application of the fixing pads. This is advisable where metal fittings have a residual post-production oil film, in which case batch or selective degreasing is carried out. In most instances it is not necessary to pre-prepare the container surface.
The in-built adjustment facilitated by variable spacer thickness also allows for building tolerances and different typologies to be accommodated. Framing studs and joists can be shimmed and leveled through'. Differing wall, roof, lining and cladding permutations can be put together and containers can be linked together as multiple units joined and opened through to form larger volumes without the need for unsightly cover strips or changes in level or boxing-out junctions between module joins. Adjustments and voids can be made to accommodate building services concealed within the fabric of the building.
The intermediate stud to wall fixings typically comprises an assembly of Lafarge Dryliner fittings; RD2 winged bracket bolted onto RD7 bracket using an M6x12 set screw.
The ability to interlock and slide the fixing brackets to any position along the length of the pressed metal studs is also desirable, giving the system inherent flexibility.
Typical Process and Sequence of Works By way of example only, typically the process and sequence of assembly of the interior framing, insulation and lining out for converting a shipping container would be as follows; 1. Mark-up setting out positions onto the face of the surface or area being worked on in accordance with design/setting out data.
2. Cut selected metal studs, joists, angles etc. to the required length in accordance with design/setting out data.
3. Screw the fix floor track section (typically Lafarge RD9or similar) to the container wooden floor suitable to receive vertical wall studs.
4. Position vertical metal wall studs (typically Lafarge RDI or similar), complete with pre-applied adhesive fixing pad/bracket assembly at upper end. Firstly slot stud into matching friction fitting floor rail then push top of stud towards upper wall position and firmly push to affix in position by way of self-adhesive fixing pad. Typically studs would be fixed at 600mm centres to suit a plasterboard lining system. The bottom stud to rail fixing is typically by means of self-piercing, self-tapping screws.
5. Once the requisite number of vertical studs are in place, an angled top rail (typically Lafarge MFC2525 or similar), is put in place across the studs at ceiling level, held in position by holding magnets. Once in position the top rail is typically fixed in position to each vertical stud by means of self-piercing, self-tapping screws.
6. Once the top (ceiling) angle is fixed in place the ceiling joists (typically Lafarge C stud CS5O spliced together or similar), are positioned on top of the top rail, typically adjacent to each corresponding stud and fixed to the angle by means of self-piercing, self-tapping screws.
7. Next the intermediate stud to wall fixings are pushed into place on the vertical studs (a push-lock fit), and slid to the requisite setting out, typically 2no. at approximately 800mm centres.
8. Once in place the serrated and perforated wings of the RD 2 (intermediate fixing) component are bent towards but not touching the container surface -typically within 15mm -to allow for fixing to the container by means of localized polyurethane adhesive foam fix (typically lnsta-Stik fast cure by Dow) 9. Openings formed for windows, doors, services and the like are framed and trimmed using the same techniques and components together with similar variants.
10. Interior partition walls, corners, boxing-out and other framing-out/lining requirements are framed and trimmed using the same techniques and components together with similar variants.
11. As the erection and fixing of the framing proceeds, it interlocks and joins together, gaining strength and stability from the multiple interconnecting framing fixtures. In this way the finished frame becomes inherently strong.
12. Once the framing assembly is complete, the entire framing assembly is checked for final compatibility with setting-out to suit the design drawings, layout and follow-on lining/board-out 13. Masking tape is then applied as necessary to the faces of the framing or to sensitive parts of the building fabric, prior to application of spray applied polyurethane insulation.
14. The interior walls, ceiling and parts of the floor of the container are then sprayed with polyurethane insulation (PUR). This part of the process ensures; All fixing brackets and any appropriate framing elements are securely fixed and embedded in place with spray applied PUR insulation or the like. The walls, ceiling and parts of the floor are fully covered with high performance insulating PUR insulation or the like.
15. A composite quilt of rockwool/mineral fibre/silver reflective foil/spacetherm or similar multi-layer insulation material is then incorporated within the wall/ceiling/floor linings to suit requisite design criteria.
16. Building services including electrics, plumbing data comms are typically laid in either before, during or after the insulating quilt.
17. Finally the lining/boarding out which may typically be plasterboard is carried out, followed by finishing and decorating to completion.
Typical Drawing Details An example of the invention will now be described, by way of example only, with reference to the accompanying provisional drawings, in which; Figure 1 is a sectional isometric view of an unconverted shipping container.
Figure 2 is a sectional isometric view of a converted shipping container where; I is a top stud fixing bracket, 2 is an intermediate stud fixing bracket, 3 is a floor track, 4 is a wall stud, 5 is polyurethane wall insulation, 6 is polyurethane ceiling insulation, 7 is polyurethane floor insulation, 8 is a ceiling joist, 9 is the insulation quilt,1O is plasterboard finish, 11 is the floor finish, 12 is a formed window opening, 13 is a formed door opening Figure 3 is an isometric view of a foam fixing pad where; 1 is a pressure-sensitive, high-strength, high-tack self-adhesive, acrylic foam tape or pad, 2 is a closed cell rigid pvc insulating spacer board which can be of varying thickness to suit the application, 3 is a peel-off adhesive protection film, 4 the dimensions are variable to suit the application.
Figure 4 is a sectional isometric view of a top of stud foam fixing bracket where; 1 is a foam fixing pad, 2 is an RD7 bracket, 3 is an RDI stud Figure 4A is a sectional elevation view of a top of stud foam fixing bracket where; us a foam fixing pad, 2 is an RD7 bracket, 3 is an RD1 stud, 4 is the container wall surface to which the bracket is affixed, Figure 5 is a sectional isometric view of an intermediate fixing bracket where; I is an RD1 stud, 2 is an RD7 bracket, 3 is an RD2 winged bracket to be bent to the desired set, 4 is an M6x12 set screw Figure 5A is a sectional elevation view of an intermediate fixing bracket where; 1 is an RD1 stud, 2 is an RD7 bracket, 3 is an RD2 winged bracket bent to the desired set, 4 is an M6x12 set screw, 5 is localized instant-foam fixing, 6 is the container wall surface to which the bracket is affixed.
Figure 5B is a sectional elevation view of a wall conversion where, 1 is the original container structure, 2 is the polyurethane foam roof insulation, 3 is the polyurethane foam wall insulation, 4 is the polyurethane foam floor insulation, 5 is a top stud fixing bracket, 6 is an intermediate stud fixing bracket, 7 is a vertical wall stud, 8 is a ceiling joist, 9 is a floor track, is the finished floor, 11 is an angled top rail, 12 is quilted multi-layer ceiling insulation, 13 is quilted multi-layer wall insulation, 14 is additional floor insulation/underlay, 15 is space for services, 16 is a steel box section of the shipping container, 17 is a steel box section of the shipping container
Claims (16)
- Claims 1. An integrated building system comprising of fixing devices, framing apparatus, method and process to convert steel enclosures including ISO shipping containers into habitable buildings.
- 2, A building system according to claim 1 in which the fixing devices and framing apparatus comprising of light-gauge steel components and including but not limited to wall stud, floor channel, intermediate fixing bracket, winged bracket, ceiling track and top-stud are set-out, held together and temporarily fixed to the inside surface of the shipping container by various means including but not limited to holding magnets, self-adhesive foam pads, friction fittings, mechanical fixings and dabs of spray applied polyurethane foam insulation or similar spray foam insulation.
- 3. A building system according to claim 1 in which the fixing devices and framing apparatus comprising of light-gauge steel components and including but not limited to wall stud, floor channel, intermediate fixing bracket, winged bracket, ceiling track and top-stud are permanently fixed together and to the inside surface of the shipping container by various means including but not limited to, friction fittings, mechanical fixings and embedded encapsulation either partially or fully by means of spray applied polyurethane foam insulation or similar spray foam insulation.
- 4. A building system according to claim 1, in which the fixing devices and framing apparatus interconnect, interlock and fix together to form a rigid secondary framework that is to a substantial degree both thermally and acoustically isolated from the steel shell of the shipping container, and into and onto which is placed insulation, services, doors, windows and interior linings to form a habitable building.
- 5. Fixing devices according to claim 1, in which the steel fixings and framing apparatus may have one or more self-adhesive foam fixing pads affixed to them, as, when, and where required, such that the fixing or framing component can be fixed into position, either onto the * inside surface of the shipping container or onto another fixing or framing component by means of simple hand applied pressure to bring the component surfaces together with the foam fixing pad situated in between, such that the fixing pad provides a secure fixing bond between the surfaces being brought into contact with one another.
- 6. A self-adhesive foam fixing pad according to claim 5, in which the fixing pad is composed of resilient cellular foam material or another material composition offering similarly desirable * characteristics including but not limited to, resilience, thermally insulating, temperature stability, resistance to aging and effective acoustic separation, and which may also include enhanced multi-laminate compositions where desirable. ** * * * **
- 7. A self-adhesive foam fixing pad according to claim 6, in which the fixing pad comprises of single or multiple pre-cut pre-finished pieces ready for use, or sheets or rolls which may be * pie-marked or processed for later division into individual useable pieces as required.
- 8. A self-adhesive foam fixing pad according to claim 7, in which the fixing pad can be of different and variable thickness to facilitate a differing degree of separation between affixed components where it may be desirable either to increase or reduce thedegree of separation between internal and external environmental conditions such that detrimental phenomenon including but not limited to cold-bridging and sound transmission can be controlled by the thickness of, and thereby the degree of separation afforded by the foam fixing pad.
- 9. A self-adhesive foam fixing pad according to claim 8, in which the fixing pad can be of different shape, size and composition to facilitate either a more or less efficacious surface contact and adhesion onto or between different sizes and shapes of fixings or apparatus or to facilitate a differing degree of adhesion onto or between affixed components where it may be desirable either to increase or reduce the degree of adhesion between components being fixed depending on whether it is for setting out purposes or permanent fixing.
- 10. A self-adhesive foam fixing pad according to claim 9, in which the means of adhesion on each surface of the pad requiring adhesive is provided by an acrylic based adhesive or another adhesive material offering similarly desirable characteristics including but not limited to pressure-sensitivity, high-tack, durability, high-strength and conformable adhesion when pressed into position.
- 11. A self-adhesive foam fixing pad according to claim 10, in which the adhesive surface is protected up until its point of use in providing adhesion by means of peel-off disposable protective tape or other similarly effective means of barrier protection to cover the adhesive prior to use.
- 12. A building system according to any of the preceding claims in which spray applied polyurethane foam insulation or similar spray foam insulation is applied to partially or fully encapsulate, embed or otherwise cover the fixings, apparatus and exposed inside surface of the shipping container such that the encapsulation and embedment acts to permanently cover the inside surface of the container and fix components to it and into their respective positions, and acts to prevent internal and interstitial condensation, reduce heat loss and heat gain from inside to outside the building and vice versa, facilitate an airtight and watertight construction, and reduce acoustic transmission from inside to outside the building and vice versa.
- 13. A building system according to claim 12 in which spray applied polyurethane foam insulation or similar spray foam insulation can be applied in varying and variable depth of cover to the fixings, apparatus and exposed interior surface of the shipping container.
- 14. A building system according to any of the preceding claims whereby all or some of the building system including the components, tooling, building materials, information and know-how required to construct a habitable building is packaged or pre-packaged such that a kit or kits of parts can be delivered to a site or be put into a shipping container or shipping containers to be delivered to a site.
- 15. A building system according to claim 14 whereby the kit or kits of parts together with the shipping container or shipping containers collectively comprise sufficient components, tooling, u. . information and know-how to be able to construct a habitable building.Amendments to the claims are as follows Claims 1. An integrated building system comprising of wall panels, fixing devices, framing apparatus, method and process to convert Shipping Containers into habitable buildings.2. A building system according to claim I in which the fixing devices and framing apparatus comprising of lightweight pressed metal framing sections and components and including but not limited to wall stud, floor tracl section, intermediate fixing bracket, winged bracket, angled top rail and top-stud are set-out, held together and temporarily fixed to the inside surface of the shipping container by various means including but not limited to holding magnets, self-adhesive foam pads, friction fithngs, mechanical fixings and dabs of spray applied polyurethane foam insulation or similar spray foam insulation.3. A building system according to claim I in which the fixing devices and framing apparatus comprising of light-gauge steel components and including but not limited to wall stud, floor track section, intermediate fixing bracket, angled top rail, winged bracket, and top-stud are permanently fixed together and to the inside surface of the shipping container by various means including but not limited to, friction fittings, mechanical fixings and embedded encapsulation either partially or fully by means of spray applied polyurethane foam insulation or similar spray foam insulation.4. A building system according to claim I, in which the fixing devices and framing apparatus interconnect, interlock and fix together to form a rigid secondary framework that is to a substantial degree both thermally and acoustically isolated from the steel shell of the shipping container, and into and onto which is placed insulation, services, doors, windows and interior linings to form a habitable building.5. Fixing devices according to claim I, in which the steel fixings and framing apparatus may have one or more self-adhesive foam fixing pads affixed to them, as, when, and where required, such that the fixing or framing component can be fixed into position, either onto the inside surface of the shipping container or onto another fixing or framing component by means of simple hand applied pressure to bring the component surfaces together with the foam fixing pad situated in between, such that the fixing pad provides a secure fixing bond between the surfaces being brought into contact with one another.6. A self-adhesive foam fixing pad according to claim 5, in which the fixing pad is composed of a pressure-sensitive, high strength, high-tack self-adhesive acrylic foam tape or pad material or another material composition offering similarly desirable characteristics including but not limited to, resilience, thermally insulating, temperature stability, resistance to aging and effective acoustic separation, and which may also include enhanced multi-laminate compositions where desirable.7. A self-adhesive foam fixing pad according to claim 6, in which the fixing pad comprises of single or multiple pre-cut pre-finished pieces ready for use, or sheets or rolls which may be pre-marked or processed for later division into individual useable pieces as required.8. A self-adhesive foam fixing pad according to claim 7, in which the fixing pad can be of different and variable thickness to facilitate a differing degree of separation between affixed components where it may be desirable either to increase or reduce the degree of separation between internal and external environmental conditions such that detrimental phenomenon including but not limited to cold-bridging and sound transmission can be controlled by the thickness of, and thereby the degree of separation afforded by the foam fixing pad.9. A self-adhesive foam fixing pad according to claim 8, in which the fixing pad can be of different shape, size and composition to facilitate either a more or less efficacious surface contact and adhesion onto or between different sizes and shapes of fixings or apparatus or to facilitate a differing degree of adhesion onto or between affixed components where it may be desirable either to increase or reduce the degree of adhesion between components being fixed depending on whether it is for setting out purposes or permanent fixing.10. A self-adhesive foam fixing pad according to claim 9, in which the means of adhesion on each surface of the pad requiring adhesive is provided by an acrylic based adhesive or another adhesive material offering similarly desirable characteristics including but not limited to pressure-sensitivity, high-tack, durability, high-strength and conformable adhesion when pressed into position.11. A self-adhesive foam fixing pad according to claim 10, in which the adhesive surface may be protected up until its point of use in providing adhesion by means of peel-off disposable protective tape or other similarly effective means of barrier protection to cover the adhesive prior to use.12. A building system according to any of the preceding claims in which spray applied polyurethane foam insulation or similar spray foam insulation is applied to partially or fully encapsulate, embed or otherwise cover the fixings, apparatus and exposed inside surface of the shipping container such that the encapsulation and embedment acts to permanently cover the inside surface of the container and fix components to it and into their respective positions, and acts to prevent internal and interstitial condensation, reduce heat loss and heat gain from inside to outside the building and vice versa, facilitate an airtight and watertight construction, and reduce acoustic transmission from inside to outside the building and vice versa.13. A building system according to claim 12 in which spray applied polyurethane foam insulation or similar spray foam insulation can be applied in varying and variable depth of cover to the fixings, apparatus and exposed interior surface of the shipping container.14. A building system according to any of the preceding claims whereby all or some of the building system including the components, tooling, building materials, information and know-how required to construct a habitable building is packaged or pre-packaged such that a kit or kits of parts can be delivered to a site or be put into a Shipping Container to be delivered to a site.15. A building system according to claim 14 whereby the kit or kits of parts together with the Shipping Container or Shipping Containers collectively comprise sufficient components, tooling, information and know-how to be able to construct a habitable building.
- 16. A building system according to any of the preceding claims in which Shipping Containers may be linked together as multiple units or modules joined together and opened through to form larger volumes without the need for unsightly cover strips or changes in level or boxing out junctions between module joins.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0908086A GB2472761A (en) | 2009-05-12 | 2009-05-12 | System for constructing buildings from converted steel containers |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0908086A GB2472761A (en) | 2009-05-12 | 2009-05-12 | System for constructing buildings from converted steel containers |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0908086D0 GB0908086D0 (en) | 2009-06-24 |
| GB2472761A true GB2472761A (en) | 2011-02-23 |
Family
ID=40833816
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0908086A Withdrawn GB2472761A (en) | 2009-05-12 | 2009-05-12 | System for constructing buildings from converted steel containers |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2472761A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE202016106380U1 (en) | 2016-11-15 | 2016-12-19 | Michael Haiser | apartment |
| WO2018091137A1 (en) | 2016-11-15 | 2018-05-24 | Haiser, Michael | Residential block and method for producing a thermal insulation |
| WO2023285301A1 (en) * | 2021-07-14 | 2023-01-19 | Martin Schuster | Stackable and road-transportable micro modular house |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3208302A1 (en) * | 1981-03-09 | 1982-09-23 | Robert Haefelfinger | Arrangement for living or other useful purposes |
| JPH09195533A (en) * | 1996-01-19 | 1997-07-29 | Nippon Fuaiaa Utsudo Kk | Simplified housing and construction thereof by use of container for ocean transportation |
| GB2423315A (en) * | 2003-10-17 | 2006-08-23 | Big Steps Ltd | Building modules |
| GB2426015A (en) * | 2005-05-09 | 2006-11-15 | Shih Ghee Ng | Insulated ISO container used as a portable greenhouse |
-
2009
- 2009-05-12 GB GB0908086A patent/GB2472761A/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3208302A1 (en) * | 1981-03-09 | 1982-09-23 | Robert Haefelfinger | Arrangement for living or other useful purposes |
| JPH09195533A (en) * | 1996-01-19 | 1997-07-29 | Nippon Fuaiaa Utsudo Kk | Simplified housing and construction thereof by use of container for ocean transportation |
| GB2423315A (en) * | 2003-10-17 | 2006-08-23 | Big Steps Ltd | Building modules |
| GB2426015A (en) * | 2005-05-09 | 2006-11-15 | Shih Ghee Ng | Insulated ISO container used as a portable greenhouse |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE202016106380U1 (en) | 2016-11-15 | 2016-12-19 | Michael Haiser | apartment |
| WO2018091137A1 (en) | 2016-11-15 | 2018-05-24 | Haiser, Michael | Residential block and method for producing a thermal insulation |
| CN110402312A (en) * | 2016-11-15 | 2019-11-01 | 沃克爱因斯有限责任公司 | Inhabitation block and method for manufacturing heat insulation structural |
| US10889979B2 (en) | 2016-11-15 | 2021-01-12 | Werk Eins Gmbh | Habitation block and method for producing thermal insulation |
| RU2746422C2 (en) * | 2016-11-15 | 2021-04-13 | Верк Айнс Гмбх | Residential building and method of manufacture of thermal insulation |
| WO2023285301A1 (en) * | 2021-07-14 | 2023-01-19 | Martin Schuster | Stackable and road-transportable micro modular house |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0908086D0 (en) | 2009-06-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |