NZ741629A - A Building Frame - Google Patents

Abstract

It is known to have buildings designed for transport in the manner of a freight container. However they have limited features to facilitate both shipping and stacking for forming multi-level buildings. It is accordingly an object of a preferred embodiment of the invention to go at least some way towards addressing this. In a preferred embodiment there is a building frame 1 substantially in the shape of a rectangular prism. It has corner removable castings 2 to facilitate stacking with a substantially similar frame generally in the manner of ISO freight containers, each casting protruding in the height, width and length dimensions with respect to the rest of the frame. owards addressing this. In a preferred embodiment there is a building frame 1 substantially in the shape of a rectangular prism. It has corner removable castings 2 to facilitate stacking with a substantially similar frame generally in the manner of ISO freight containers, each casting protruding in the height, width and length dimensions with respect to the rest of the frame.

Description

TITLE A Building Frame FIELD OF INVENTION A preferred form of this invention relates to a portable building frame, with or without cladding.

BACKGROUND An intermodal container is a large standardized shipping container, designed and built for freighting products. They are referred to as ‘intermodal’ as they can be used across different modes of transport – from ship to rail to truck – without unloading and reloading their contents. They are particularly used to store and transport materials and products efficiently and securely in the global shipping industry, although some are only used in- country. Such containers shipped internationally are usually in the form “ISO” containers and they are expected to conform to certain height, width and length dimensions.

ISO shipping containers have ‘corner castings’ with openings for twist lock fasteners at each of their eight corners. These enable the container to be attached to a crane or hoist from the top, bottom or side, to facilitate lifting and moving. The corner castings also enable containers to be locked to one another, for example when they are stacked vertically. In this regard ISO containers are sometimes stacked on a ship up to ten high.

It is known to form buildings so they are in the general shape of an ISO freight container when shipped. An example of this is described in patent specification WO2005106147 by the inventor Gibson. However that building, when assembled, is for use on one level.

The document provides no teaching as to how to construct a multi-level building from freight containers.

OBJECT OF THE INVENTION It is an object of preferred embodiments of the invention to go at least some way towards facilitating the construction of a multi-level building from containers-like frame modules.

While this applies to preferred embodiments, it should be understood that the object of the invention per se is simply to provide the public with a useful choice. Therefore any objects applicable to preferred embodiments should not be taken as a limitation on the scope of claims expressed more broadly.

The term “comprises” or derivatives thereof should not be interpreted as limiting. For example if used in relation to a combination of features it should be taken to indicate that optionally, but not necessarily, there may be additional features that have not been mentioned.

SUMMARY OF INVENTION According to one aspect of the invention there is provided a building frame substantially in the shape of a rectangular prism, comprising removable corner castings sufficient for the frame to be stacked to another substantially similar frame, by way of the castings, in the manner of an ISO freight container, each casting protruding in the height, width and length dimensions of the rest of the frame.

The reference to ‘prism’ does not mean that the frame is necessarily clad; it simply indicates the general outline. The building frame may or may not be clad. Further, the reference to ‘stacking in the manner of an ISO freight container’ does not mean that the frame has to have the same dimensions as an ISO freight container; it might or might not have such dimensions.

Optionally the frame has corner posts each comprising a ledge, wherein a corner casting sits on and is fastened to the ledge.

Optionally each ledge has holes for receiving fasteners to secure the corner casting to the ledge.

Optionally the frame has tapered locators that can be fastened to the frame at substantially the same places as the corner castings, when removed, such that in each case that the taper of the locator is outside the frame and is arranged for guiding another substantially similar frame into an accurate corner-to-corner stack with the first mentioned frame.

Optionally the frame is formed substantially in the length and width gauge of an ISO freight container.

Optionally the frame is formed to have a height gauge larger than the largest height prescribed for an ISO freight container.

Optionally the frame is formed to have a height gauge substantially the same as that of an ISO freight container.

Optionally the frame the corner castings are ISO twist-lock castings.

Optionally the frame comprises cladding.

Optionally the frame has the shape and stacking strength of an ISO shipping container.

According to a further aspect of the invention there is provided a method of forming a building, at least in part, from a plurality of building frames as set out above, comprising the steps: a) detaching the corner castings from a lower one of the building frames; b) fitting the locators to positions previously occupied by the corner castings; c) raising a second building frame above the lower one; and d) lowering the second building frame so it contacts at least some of the locators and is guided by them into accurate corner-to-corner stacked alignment with the lower container.

Optionally a further one or more of the building frames are stacked in substantially the same way to create a building more than two levels high.

DRAWINGS Some preferred embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, of which: Figure 1 is an isometric view of a building frame for use in forming a building; Figure 2 is a close-up isometric view showing the corner of two of the frames when stacked; Figure 3 is an isometric view showing corner casting detail of one of the frames; Figure 4 is an isometric view showing corner detail with the casting removed; Figure 5 is an isometric view showing corner detail with the casting replaced by a locator for guiding-in the further frame in stacking relationship at a building site; Figure 6 illustrates two of the frames aligned for stacking; Figure 7 illustrates two of the frames when stacked at a building site; Figure 8 illustrates corner detail of two of the frames when stacked; and Figure 9 shows a multi-level building being made by stacking rows of the frames.

DETAILED DESCRIPTION Referring to figure 1, a structural frame 1 for a building is in the shape of a rectangular prism. It has dimensions and strength compatible with ISO freight container standards.

In this case the frame 1 is in the footprint of a 20 foot ISO container but in other embodiments it may coincide with a 40 foot ISO footprint. To facilitate crane-lifting and stacking, the frame 1 has ISO container-type detachable corner castings 2, one at each of its eight corners. The castings 2 are preferably of an ISO twist-lock type.

The frame may be in the standard height of an ISO container, but in preferred embodiments it is ‘oversize’ so as to provide for a greater ceiling height in the finished building. The frame is therefore preferably ISO gauge in terms of its width and length, but not in its height. In the case of an oversized high gauge the sea shipping costs may be more seeing as fewer will fit into a stack. For example three stacked frames 1 may occupy same the height as four ISO containers. However the extra shipping costs will in most cases be offset by the higher market value of a building with a greater ceiling height.

That said, in other embodiments, one or other of the normal ISO height dimensions may be adopted.

Referring to figure 2, when two of the frames 1 are stacked for shipping, the adjacent corner castings 2 are locked to one another. In other words the four upper corner castings 2 of the lower frame lock, respectively, with the four lower corner castings of the frame 1 above.

With further reference to figure 2, when two frames 1 are stacked for shipping there is a significant gap 3 between the bottom 4 of the upper frame 1 and the top 5 of the lower frame 1. The gap is due to the way the corner castings 2 protrude from the rest of the frame 1 in terms of height and width, ie just as the corner castings of an ISO container do.

Because the frame’s corner castings 2 protrude laterally there is also a gap between frames 1 if butted side by side, or end to end.

As indicated in figure 3, the corner castings 2 are detachable from the rest of the frame 1.

This is differs from ISO shipping containers, which have corner castings formed integrally with the main superstructure. In the figure 3 embodiment, each corner casting 2 sits on a ledge 6 of one of the frame’s corner posts. The casting 2 is releasably secured there by way of bolts 8 or some other suitable means, eg pins, etc. As shown, the ledge 6 is set into the corner post. Because the footprint and height of the casting 2 is larger than those of the ledge, the casting protrudes from the rest of the container in all three dimensions.

Referring to figures 4, 5 and 6, when the frame 1 has been delivered to a building site for use in forming a multi-level building, the corner castings 2 are removed. In this instance the frame 1 is to provide the superstructure of the ground level, and a similar frame will be stacked on it. As indicated, each upper corner casting 2 of the ground level frame 1 is replaced a locator 7. This sits on and is removably bolted to the same ledge 6 that was occupied by the casting 2.

Referring to figure 4, each locator 7 has a lower L-shaped portion 9 adapted to nest into the corner of the ledge 16, and an upper tapered portion 10 for guiding the upper frame into place as it is stacked onto the ground frame. As indicated, the tapered portion 10 is L- shaped in transverse cross-section such that when in place it is offset from the footprint of the frame 1. In other words it is outside both the lateral and longitudinal edges of the frame’s corner. Going from top to bottom, the tapered portion angles in towards the frame Figure 6 shows the upper frame 1a lined up for placement on the lower frame 1b. As illustrated, the lower corners of the upper frame are directly above the upper corners of the other frame. When the upper frame 1a is lowered, the locators 7, and in particular the tapered portions 10, guide it into accurate alignment with the lower frame 1b. The locators 7 can then be removed. The use of the removable corner castings 2 means that the frames 1a and 1b can be conveniently fabricated in a factory and transported with ease in a manner the same or similar to that of ISO freight containers.

Figures 7 and 8 show the two frames 1a and 1b when stacked. As best seen in figure 8, the lower corners of the top frame 1a are perfectly aligned with the upper corners of the lower frame 1b. As the corner castings 2 were removed prior to stacking at the building site, the two frames 1a, 1b sit on one another without the significant gap 3 that would apply in a shipping stack.

Figure 9 shows a multi-level building being constructed from larger side-by-side stacks of the frames 1. It has six levels above ground and is several frames wide and long. The basement level 1c may be used for building services, etc or, if larger, may provide a carpark. The frames 1 can be secured side-by-side by way or bolts or pins that pass through the bolt holes by which the corner castings 2 were bolted to the corner posts of each frame 1.

In some embodiments of the invention the building frame 1 may be clad prior to shipping.

The cladding may provide end and side walls, and more preferably a roof or ceiling and floor as well.

While preferred forms of the invention have been described by way of example, it should be understood that modifications and improvements can occur without departing from the scope of the following claims.

Claims (14)

1. A building frame substantially in the shape of a rectangular prism, comprising removable corner castings sufficient for the frame to be stacked to another substantially similar frame, by way of the castings, in the manner of an ISO freight 5 container, each casting protruding in the height, width and length dimensions of the rest of the frame.

2. A building frame according to claim 1, comprising corner posts each comprising a ledge, wherein a corner casting sits on and is fastened to the ledge.

3. A building frame according to claim 2 wherein each ledge has holes for receiving fasteners to secure the corner casting to the ledge.

4. A building frame according to claim 1, 2 or 3, comprising tapered locators that can 15 be fastened to the frame at substantially the same place as the corner castings, when removed, such that in each case that the taper of the locator is outside the frame and is arranged for guiding another substantially similar frame into an accurate corner-to-corner stack with the first mentioned frame. 20

5. A building frame according to any one of the preceding claims formed substantially in the length and width gauge of an ISO freight container.

6. A building frame according to claim 5, formed to have a height gauge larger than the largest height prescribed for an ISO freight container.

7. A building frame according to claim 5, formed to have a height gauge substantially the same as that of an ISO freight container.

8. A building frame according to any one of the preceding claims, wherein the corner 30 castings are ISO twist-lock castings.

9. A building frame according to any one of the preceding claims, comprising cladding. 35

10. A building frame according to any one of the preceding claims, generally having the shape and stacking strength of an ISO shipping container.

11. A building frame according to claim 1, wherein: a) the frame incorporates corner posts each comprising a ledge, and wherein a corner casting sits on and is fastened to the ledge; b) each ledge has holes receiving fasteners to secure the corner casting to 5 the ledge; c) there is a plurality of tapered locators that can be fastened to the frame at substantially the same places as the corner castings, when removed, such that in each case that the taper of the locator is outside the frame and is arranged for guiding another substantially similar frame into an accurate 10 corner-to-corner stack with the first mentioned frame; and d) the frame is substantially in the length and width gauge of an ISO freight container.

12. A building frame substantially as herein described with reference to the 15 accompanying drawings.

13. A method of forming a building, at least in part, from a plurality of building frames each in accordance with claim 4, or any of claims 5 to 11 when read back on claim 4, comprising the steps: 20 e) detaching the corner castings from a lower one of the building frames; f) fitting the locators to positions previously occupied by the corner castings; g) raising a second building frame above the lower one; and h) lowering the second building frame so it contacts at least some of the 25 locators and is guided by them into accurate corner-to-corner stacked alignment with the lower container.

14. A method according to claim 13, wherein a further one or more of the building frames are stacked in substantially the same way to create a building more than 30 two levels high.