WO2007041757A1

WO2007041757A1 - Multi-dwelling structure and method to construct same

Info

Publication number: WO2007041757A1
Application number: PCT/AU2006/001410
Authority: WO
Inventors: Robert Peter Fuller
Original assignee: Fullicus Pty Limited
Priority date: 2005-10-11
Filing date: 2006-09-27
Publication date: 2007-04-19
Also published as: CN101297087A

Abstract

A permanent or semi-permanent multi-dwelling structure is constructed from a plurality of modular units. Each unit has a size and a shape compatible to a shipping container. At least some of the units are arranged to be adjacent to each other.

Description

MULTI-D WELLING STRUCTURE AND METHOD TO CONSTRUCT SAME

TECHNICAL FIELD

The present invention relates to a permanent multi-dwelling structure and a method of constructing the same. In particular the invention relates to a permanent multi-dwelling structure constructed from a plurality of shipping containers and a method of assembling the plurality of shipping containers into a multi-dwelling structure.

BACKGROUND OF THE INVENTION

Shipping containers have previously been used for housing purposes. Most of these applications, however, include the use of a single container suitably arranged or recycled for providing a shelter. Such an arrangement is unsuitable for providing large scale accommodation in a very short time scale. Recent natural disasters such as the Tsunami's in Indonesia and Sri Lanka in December 2004, and Hurricanes Rita and Katherine that struck the Gulf of Mexico in September 2005, provide a good example of how a large scale accommodation for thousands of people may suddenly become necessary and have to be provided on a very short notice and within a very short period. It is clear that multi-dwelling structures are the only solution in such situation.

US Publication 2003/0188507 Al discloses modular multi-use shelters constructed by assembling a plurality of shipping containers converted into a multi-element structure wherein each shipping container is joined to the rest by means of the standard mechanisms that are normally provided to interlock modular shipping containers during shipping. While multi-use structures such as prisons or jail facilities have been mentioned in this document, the system described there is limited to each container being used as a relatively independent entity. The only connection between the containers disclosed in this publication refers to interior passages provided between adjacent containers. Furthermore, no indication has been given as to the arrangement of the facilities related to various utilities such as supply of water electricity, heating and sewerage removal. Thus, while the large number of containers discussed there can offer a large scale of accommodation, because of the fact that each container has been used substantially and possibly serviced individually, a lot of the potential flexibility provided by such a multi-dwelling system has not been utilised. SUMMARY OF THE INVENTION

According to one aspect of the invention, there is provided a permanent or semipermanent multi-dwelling structure constructed from a plurality of modular units, each unit having a size and a shape compatible to a shipping container, wherein at least some of the units are arranged to be adjacent to each other.

Preferably, at least some adjacent units are configured to complement each other such that a plurality of complimentary units forms an integral part of a single dwelling.

Also preferably, at least a part of at least one utility service is common for at least some of the dwellings.

Even more preferably, the utility service is one of water, heating, gas and electricity supply or sewerage removal.

Preferably, at least two units are arranged to define at least one multi-storey structure within the multi-dwelling structure.

Also preferably, at least a part of the access-ways or the upper storey stairways are common for at least some of the dwellings.

Preferably, at least some of the complimenting adjacent units are disposed next to each other.

According to a second aspect of the invention, there is provided a method for constructing a permanent or semipermanent multi-dwelling structure from a plurality of modular units having a size and a shape compatible to a shipping container of predetermined size and shape, the method comprising the steps of: using the predetermined size and shape to define a grid of foundation points; and inserting foundations at the foundation points.

Preferably, the foundations points are chosen to correspond to the corner points of the corresponding modular units. Also preferably, the method comprises the steps of affixing a plurality of modular units in an adjacent and/or stacked configuration, each unit being affixed to foundation points and/or to an adjacent unit.

Preferably, at least some adjacent units are configured for complementing each other such that a plurality of complementary units form an integral part of a single dwelling, wherein before the step of affixing the units, the method further comprises the step of arranging respective complementary units such that to, upon affixing, form the corresponding dwellings.

Also preferably, the method further comprises the step of installing modular facilities for at least one utility service, such as water, heating, gas, electricity or sewerage removal, such that at least part of the at least one service is common for at least some of the dwellings.

Also preferably, at least a part of the step of installing the at least one utility is based on the predetermined dimensions of the units and precedes the step of affixing the modular units to corresponding foundations points.

Preferably, during the step of affixing of the units, at least one unit is stacked on the top of another unit to define a multi-storey structure.

Also preferably, the method further comprises the step of installing at least a portion of an access-way or upper storey stairway to be common for at least some of the dwellings.

According to a further aspect of the invention, there is provided a permanent or semipermanent multi-dwelling structure constructed from a plurality of modular units, each unit having a size and a shape compatible to a shipping container, the units being arranged in adjacent and/or stacked configuration, the structure comprising at least one modular utility service that is common for a plurality of dwellings.

Preferably, the utility service is one of water, heating, gas and electricity supply or sewerage removal. According to another aspect of the invention, there is provided a method for constructing a permanent or semipermanent multi-dwelling structure from a plurality of modular units, each unit having a size and a shape compatible to a shipping container of predetermined size and shape, the method comprising the steps of: laying out a grid of foundation points based on the predetermined size and shape of the units; and affixing a plurality of modular units in an adjacent and/or stacked configuration, each unit being affixed to foundation points and/or to an adjacent unit.

Preferably, the method further comprising the step of installing modular facilities for at least one utility service, such as water, heating, gas, electricity or sewerage removal, such that at least part of the at least one utility service is common for at least some of the dwellings.

Also preferably, in relation to any of the preceding multi-dwelling structures or methods of construction thereof, the size and shape of at least some of the modular units are ISO compliant.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention will now be described by way of example only and with reference to the accompanying drawings wherein:

Fig. 1 is a schematic front elevation view of a three storey dwelling structure according to one embodiment of the invention.

Fig. 2(a) is a schematic side elevation view of the structure of Fig. 1.

Fig. 2(b) is a schematic plan view of one of the floors of the structure in Fig. 2(a).

Fig. 3 is a schematic plan view of the rooftop of the dwelling structure of Figs. 1, 2(a) and 2(b), illustrating a solar panel system that is common for all the dwellings within the dwelling structure.

Fig. 4 is a detailed section from the schematic plan view of Fig. 2(b), showing two modular units complement each other to form a single dwellings. Fig. 5 is a schematic plan view of a second embodiment of a dwelling structure according to the invention, wherein three units complement each other to form a single dwelling.

Fig. 6 is a schematic plan view of foundation points for constructing a permanent or semipermanent multi-dwelling structure according to the invention.

Fig. 6(a) is a schematic side view of a foundation pile engaging a unit in a supporting arrangement, according to the invention.

Fig. 6(b) is a schematic plan view of the supporting arrangement of Fig. 6(a).

Fig. 7 (a) is a schematic side elevation view of a third embodiment of the multi-dwelling structure of the invention.

Fig. 7(b) is a schematic front elevation view of the multi-dwelling structure of Fig. 7(a).

PREFERRED EMBODIMENT OF THE INVENTION

As shown in Figures 1, 2(a), 2(b), 5 and 6, the permanent or semipermanent multi- dwelling structure 1 of the invention is constructed from a plurality of shipping modular units 2, having a size and shape compatible to a 40'x 8' ISO shipping container. At least some of modular units 2 within the dwelling structure are adjacent. Thus they are disposed either next to each other or are stacked on the top of each other. Notably, at least some of the adjacent to each other units are configured to compliment each other such that two or more complimentary units form a single dwelling 3, as shown in Figures 4 and 5. The fact that the units compliment each other to form a single dwelling here indicates that the connection between the units is more substantial than a single passageway between the units. In fact, the complimenting units are arranged in such a way that each unit 2 presents an integral part of a single dwelling 3, such that not a single unit, but the combination of units that actually defines the dwelling.

The multi-dwelling structure represented in the accompanying figures is a permanent or semipermanent large-scale housing complex where at least some of the dwellings share common facilities. While the complex could be one level, multi-storey structures are also envisaged, as shown in the Figures 1, 2(a), 2(b), 7(a) and 7(b). The shared facilities could include transport facilities such as access ways or stairways to the upper storey dwellings. Utility services such as provision of water, heating, gas and electricity or the removal or sewerage are also usually shared between two or more dwellings. In addition, the facilities are in a modular form wherein the modularity relates to the entire structure. For example, a water or electricity supply system is arranged in modules, which are particularly designed to fit and be installed in the context of the multi- dwelling system constructed by a plurality of units. More clarification on this point will be given further in the text where we describe the method of construction of the multi- dwelling structure.

The units 2 are preferably fabricated in a container fabrication facility. Any units, which are supposed to be combined in a complimentary engagement so as to define a single dwelling, are pre-cut at the fabrication site. Additional arrangements such as fitting claddings, insulation, or including any other utility arrangements, can also be performed at the place of fabrication. Of course any required components can also be fabricated at different places and delivered for fitting at the place of installation. Because of its specific nature of the multi-dwelling, the corresponding method of construction of the structure is also very specific. Again an important aspect is a quick, cheap, but reliable installation whereby a minimum amount of labour, and in particular skilled labour, is required.

Units are usually delivered to the respective site on standard-size semi-trailers.

However, they can also be delivered and remain on their own wheeled bogies. Because the units conform to the standard road width, length and height requirements, they can be transported anywhere by road without the need for special permits. As required, the units can remain on their own bogies and be relocated with short notice.

Usually the site for installation is prepared by using bulldozers to level the site. While the units can be directly installed on the ground, this method is not suitable for the permanent or semipermanent structure discussed in this application and is not recommended. The preferred installation method includes preparing on the ground, where the structure will be installed, a grid of foundation points, as indicated in Figure 6. The grid is defined on the basis of the predetermined size and shape of the units 2 that are to be disposed in the site. Screw pile- or other suitable machines may be used to form the foundations for the multi-dwelling structure. The foundations are usually formed to correspond to the corner points of the corresponding units so as to take advantage of the standard securing points in the corners of the units. It is envisaged that pre-manufactured slabs arranged to secure the corners of the units could also be laid next to each other and connected to each other so as to form a foundation arranged for attaching the units.

After the foundations have been formed, the site is ready for securing the units. As the units 2 have a size and shape compatible to a shipping container, they can be readily transported to the building site by conventional transporting means. Once the units have been transported near the site, a mobile crane can lift the pre-finished units directly into permanent position on, for example, prepared screw piles or stacked as normal containers to nominally three levels high. The specific arrangement for attaching the units to the foundation piles is as follows. Firstly, piles 4, chosen to suit the local ground conditions, are inserted in the foundation points. As shown in Figure 6, some of the piles 4 are used to support a single, usually a corner, unit. The piles supporting internal units would be arranged to engaged two adjacent units, as indicated in Figure 1 and Figure 6. The pile caps 5 include grout, which is expandable so as to be able to accommodate temperature variations. The pile cap plate 6 is attached on the top of the expandable grout. If necessary, shims 7 may be used to level the upper surface of the pile cap plate. A base plate 8 is then attached to the pile cap plate by means of base plate bolts 9. The base plate 8 usually includes a nipple 10, which is arranged for a complimentary engagement with a dent 11 at the bottom of the supported unit 2. The unit is bolted to the base plate 8 by means of high tensile bolts 12. The combination of nipples 10 and high tensile bolts 12 provides a flexible, yet strong connection, which is cyclone and earthquake resistant. This defines the described structure as especially suitable for disaster-relieve operations. Depending on the position of the respective pile 4, there are several possible arrangements of the pile base plates 8. If the pile 4 is supporting a corner unit 2, a single nipple 10 and a high tensile bolt arrangement is required. On the other hand, where two units 2 are adjacent to each other, the corresponding supporting base plate 8 is arranged to have two nipples 10 and two bolts 12 arrangements so as to hold both units in place next to each other, as shown in Figure 1 and indicated in Figure 6(b).

After attaching the units to the foundation points, the units are further attached to each other in a standard manner, such that each unit 2 is attached to corresponding foundation points and/or to another unit so as to define the multi-dwelling structure. Of course, when affixing the units 2 to each other, a care has to be taken so that each set of complimentary units are suitably connected to each other so as to form the single dwelling they are designed to define. As previously mentioned, the structure of the invention is preferably a multi storey one. Thus, while usually the multi-unit dwellings would be defined over a single level, it is also envisaged that complementing units on more than one level can be arranged into single multi-storey dwellings. Similarly to shipping containers, the units can be stacked up to nine high should there be a need.

Once the units 2 have been affixed, the next step is the installation of the various utility services, such as water, heating, gas and electricity supply or sewerage removal. Part of the installation of each one of these services can be performed, on the basis of the foundation grid, prior to installation of the units. Of course, this does not have to always be the case and the entire installation can be performed after the installation of the units. As it was mentioned previously, the advantage of this system is that it uses facilities, which are common for more than one dwelling. In a preferred situation, a single facility would service the entire multi-dwelling structure. It is also important that these common facility structures are in a modular form, which takes into account the multi-dwelling character of the structure. This would allow a much larger scale and much more efficient installation of the facilities. This also refers to any type of facilities such as steel stairs, access ways, rainwater collection tanks and structures, roofs, domestic water header tanks, solar electricity panels installed on the roofs, lighting, solar hot water heaters, gas cooking facilities, septic tanks and so on. All of these services are preferably arranged to serve a plurality of dwellings and to be in a form, which is arranged for easy and quick installation in a multi-dwelling environment.

The internal layouts and external design of the units 2 correspond to the specific purpose of the dwellings and the budget available. For example, in dry regions, which are constantly under fire threat, a special fire-resistant glass can be used in the glazing of the units.

With regard to the purpose of the dwellings it is envisaged that several different types of dwellings can designed and constructed, including the following: • Dwellings for special housing such as disaster relief and the like;

• Dwellings for mining and remote area housing;

• Dwellings for low income and subsidised housing;

• Communal dwellings, such as retirement homes; and

• Dwellings for medium density, two storey dwelling units for general or special purposes, such as accommodating people with disabilities.

For example, in the case of a natural disaster response, where a large number of people have to be accommodated with minimum resources, each dwelling can be based on one or two modular units, as indicated in Figures 2(a), 2(b) and 4. In such cases the external finishes, insulation and roofing can be kept to minimum or not provided at all. Alternatively, where the permanent or semipermanent multi-dwelling structure is not for basic use, but may be used in a mining community or retirement community, the quality of internal and external finish, insulation, roofing, balustrading and the like may be appropriately provided to suit the intended inhabitants and their environment. Housing design for use by mining community is shown in Figures 7(a) and 7(b).

The multi-dwelling structures discussed above are manufactured to a module of 2.438m (8'0") x 12.192m (40'0") or 6.096m (20'0") or 3.048m (10'0"). Dwelling units can be made as two dwellings per 12.192 m container unit (mining housing) or with each container unit forming part of a larger dwelling.

It should be appreciated that the disclosed permanent or semipermanent multi-dwelling structure constructed from a plurality of units provides a quick, relatively cheap and reliable way of providing a large scale accommodation accompanied by the associated utility services within a small budget and a very short time period. In addition, should there be a need for the units to be moved or totally relocated, the units and the roofs are unbolted, the units are loaded onto semi-trailers, or their own bogies are reactivated, and the units are transported to their new location, where they are re-assembled in the above described manner.

It should also be appreciated that, while a particular embodiment has been described here, the general concept of the invention extends to a much wider scope of arrangements. For example, the units referred to in this description have the size and the shape of ISO compliant shipping containers. This is chosen so because these shipping containers have standard sizes, shapes and fixing means. Thus, the units of identical dimensions are suitable for loading and transporting by ship and are easily assembled into multi-unit structures. This allows cheap and efficient transportation and assembling. However, it is envisaged that units of other shapes and sizes can also be used for the purpose of this invention.

The terms "comprising" and "including" (and their grammatical variations) as used herein are used in the inclusive sense of "having" and not in the exclusive sense of "consisting only of.

Claims

1. A permanent or semi-permanent multi-dwelling structure constructed from a plurality of modular units, each unit having a size and a shape compatible to a shipping container, wherein at least some of the units are arranged to be adjacent to each other.

2. The multi-dwelling structure of claim 1, wherein at least some adjacent units are configured to complement each other such that a plurality of complimentary units forms an integral part of a single dwelling.

3. The multi-dwelling structure of claim 1 or claim 2, wherein at least a part of at least one utility service is common for at least some of the dwellings.

4. The multi-dwelling structure of claim 3, wherein the utility service is one of water, heating, gas and electricity supply or sewerage removal.

5. The multi-dwelling structure of claim 1, wherein at least two units are arranged to define at least one multi-storey structure within the multi-dwelling structure.

6. The multi-dwelling structure of claim 5, wherein at least part of the access-ways or the upper storey stairways are common for at least some of the dwellings.

7. The multi-dwelling structure of claim 2, wherein at least some of the complimenting adjacent units are disposed next to each other.

8. A method for constructing a permanent or semi-permanent multi-dwelling structure from a plurality of modular units having a size and a shape compatible to a shipping container of predetermined size and shape, the method comprising the steps of: using the predetermined size and shape to define a grid of foundation points; and inserting foundations at the foundation points.

9. The method of claim 8, wherein the foundations points are chosen to correspond to the corner points of the corresponding modular units.

10. The method of claim 8 or claim 9, wherein the method further comprises the steps of affixing a plurality of modular units in an adjacent and/or stacked configuration, each unit being affixed to foundation points and/or to an adjacent unit.

11. The method of claim 10, wherein at least some adjacent units are configured for complementing each other such that a plurality of complementary units form an integral part of a single dwelling, and wherein before the step of affixing the units, the method further comprises the step of so arranging respective complementary units such that to, upon affixing, form the corresponding dwellings.

12. The method of claim 8, wherein the method further comprises the step of installing the facility for at least one modular utility service, such as water, heating, gas, electricity or sewerage removal, such that at least part of the at least one service is common for at least some of the dwellings.

13. The method of claim 12, wherein at least a part of the step of installing the facility for at least one modular utility service is based on the predetermined dimensions of the units and precedes the step of affixing the modular units to corresponding foundations points.

14. The method of claim 10, wherein, during the step of affixing the units, at least one unit is stacked on the top of another unit to define a multi-storey structure.

15. The method of claim 8, the method further comprising the step of installing at least a portion of an access-way or upper storey stairway to be common for at least some of the dwellings.

16. A permanent or semi-permanent multi-dwelling structure constructed from a plurality of modular units, each unit having a size and a shape compatible to a shipping container, the units being arranged in adjacent and/or stacked configuration, the structure comprising at least one modular utility service that is common for a plurality of dwellings.

17. The permanent or semi-permanent multi-dwelling structure of claim 16, wherein the utility service is one of water, heating, gas and electricity supply or sewerage removal.

18. A method for constructing a permanent or semi-permanent multi-dwelling structure from a plurality of modular units, each unit having a size and a shape compatible to a shipping container of predetermined size and shape, the method comprising the steps of: laying out a grid of foundation points based on the predetermined size and shape of the units; and affixing a plurality of modular units in an adjacent and/or stacked configuration, each unit being affixed to foundation points and/or to an adjacent unit.

19. The method of claim 18, the method further comprising the step of installing modular facilities for at least one utility service, such as water, heating, gas, electricity or sewerage removal, such that at least part of the at least one utility service is common for at least some of the dwellings.

20. The permanent or semi-permanent multi-dwelling structure of any one of claims 1, 16 and 18, wherein the size and shape of at least some of the modular units are ISO compliant.