Field of Invention

The present disclosure relates to building structures, specifically temporary and semipermanent building structure, and further specifically, to roof modules for forming such structures. The present invention also relates to mounting systems for building structures for fitness equipment.

Background

Mobile training systems have become a popular means of providing a temporary or semi-permanent training facility in areas that typically do not otherwise possess such facility. For example, mobile training systems can be used by military personnel to train in locations where space and time are limited. Some existing mobile training systems make use of conventional semi-permanent structures formed from framework and panels which can be transported and assembled on site. Such structures would then be filled with the desired freestanding fitness equipment, although this is typically inefficient logistically.

Some existing mobile training systems comprise a shipping container for storing items of fitness equipment. The items of fitness equipment stored in the shipping container are those items that can be used independently of a support structure (e.g. dumbbells, medicine balls, skipping ropes). Items of fitness equipment that require support (e.g. pull-up bars, climbing towers, power racks) are permanently secured to the interior or exterior of the shipping container by way of mechanical fasteners or the like in the walls of the shipping container. Since shipping containers can be manufactured from heavy, strong materials (e.g. steel) this may be suitable for providing structural support to the items of fitness equipment. Such systems have restricted applications, and prevailing weather conditions limit their effectiveness and range of performance. Furthermore, introducing bolt holes into the walls of the shipping container can cause issues such as water ingress into the container, particularly when no fitness equipment is secured to the bolt holes. There is therefore a need for improved systems that mitigates or ameliorates one or more of the above problems, and preferably is safer and more convenient for transportation.

Summary of Invention

According to a first aspect of the invention there is provided a roof module for connecting to an intermodal container for forming a structure. The roof module may comprise a roof surface. The roof module may comprise a frame for supporting the roof surface. The frame may comprise at least one connector for connecting to a corner fixture on said intermodal container. The connector may be connectable to a first side and to a second side of said corner fixture.

As used herein, the term ‘intermodal container’ refers to an ISO defined shipping container, sometimes known simply as a shipping container. Intermodal containers are available in a range of pre-defined sizes and are all provided with a generic corner fixture in each corner of the container which is used for securing the intermodal containers during transport, e.g. via twistlocks. The storage container may be constructed (either fully or partially) from metal, plastics materials (including reinforced plastics materials), laminate materials and/or any other suitable materials.

The present invention provides a roof module which can be quickly connected to an intermodal container to form a temporary or semi-permanent structure. Connecting the frame to the intermodal container on first and second sides creates a connection and structure significantly stronger than in existing systems. Forces applied to the roof module (e.g. wind loading etc.) are far better distributed through the whole structure and the connectors. Without wishing to be bound by theory, it is understood that connecting the frame to two sides of the corner fixture creates a significantly more rigid structure. The forces applied to the roof module and the structure can cause the roof module to twist relative to the intermodal containers. The increased rigidity causes this twisting force to be transferred to the intermodal containers, and thus the mass of the intermodal containers assists in resisting the wind loading. The overall structure is much stronger than existing systems, and can support additional loads being connected to the frame, such as items of fitness equipment. The at least one connector may comprise a first connection portion for connecting to said first side of said corner fixture. The at least one connector may comprise a second connection portion for connecting to said second side of said corner casting. The first and second connection portions may be perpendicular to each other.

The first and second connection portions may each comprise an aperture therein. The connector may further comprise at least one mechanical fastener. For example, the connector comprises first and second mechanical fasteners. The mechanical fasteners may be extendable through the apertures in the first and second connection portions e.g. for securing the first and second connection portions to said corner fixture. In alternative embodiments, the first and second connection portions may comprise projecting portions, for example, interlocking formations such as twistlocks. The interlocking formations may project from the first and second connection portions and may engage said corner fixture. In some embodiments, the first and second connection portions may be different e.g. the first connection portion may comprise an aperture and the second connection portion may comprise an interlocking formation.

The roof module may comprise a plurality of connectors. Each connector may be separately connectable to a corner fixture on one or more intermodal containers. Some or all of the plurality of connectors may be provided on the frame.

The frame may define a length. The connectors may be spaced apart in the length direction. The connectors may be configured to be connectable to first and second corner fixtures on a single intermodal container. The length direction may be perpendicular to the length of an intermodal container.

The frame may comprise a first set of connectors at a first end of the frame. The first set of connectors may be connectable to a first intermodal container. The frame may comprise a second set of connectors at a second end of the frame. The second set of connectors may be connectable to a second intermodal container. The first and/or second intermodal containers may form the walls of a structure.

The first and/or second set of connectors may comprise a pair of connectors. The first and/or second set of connectors may comprise four connectors for connecting to each of the upper corner fixtures on an intermodal container. The frame may be configured such that the roof surface extends over the intermodal containers to which it is connectable. For example, the connectors may be located such that the frame and/or the roof surface extends over the intermodal container to which it is connected.

The frame may comprise one or more trusses. The frame may comprise a first truss and a second truss. The first and/or second trusses may extend in the length direction. The first and/or second trusses may be provided with a first pair of connectors at a first end and a second pair of connectors at a second end. The first and/or second pair of connectors on the trusses may be part of the first and/or second set of connectors of the roof module. The first and second trusses may be connected by a plurality of purlins and/or joists. The plurality of purlins and/or joists may extend perpendicularly to the trusses and may extend parallel to said intermodal container. The purlins may provide additional support to the roof surface. The joists may provide additional strength to the frame. The joists may be provided at a ceiling level of the roof module.

The frame may have a width. The width may be perpendicular to the length, and may correspond to the length of an intermodal container. The plurality of purlins and/or joists may have a length approximately the same as an intermodal container. In some embodiments, the roof module may have a width corresponding to multiple intermodal containers.

The at least one connector may be connected to the first and/or second truss by a third connection portion. The third connection portion may be perpendicular to the first and second connection portions.

The roof module may comprise at least one mounting point, for example, for suspending items of fitness equipment from the roof module. The one or more items of fitness equipment comprise one or more from the group consisting of: pull-up bars, dip bars, barbell racks, weight racks, power cages and half-racks, medicine ball targets, ladders, ropes, climbing frames, punch bags, mounting points for suspension training and gymnastic equipment, landmine barbells and hinges, The Grappler™ and other rope pull systems, step-up and platform attachments, cable pulley systems, cardio equipment, storage racks, benches, safety arms, and any other suitable items of fitness equipment.

The at least one mounting point may be provided on the one or more joists. The at least one mounting point may be provided on a mounting bar. The mounting bar may be part of or connectable to the frame. The mounting bar may extend in the length direction of the frame e.g. perpendicular to the trusses.

The frame and roof surface may be configured to provide a pitched roof. The mounting bar may be located at or adjacent the apex of the pitched roof.

The at least one mounting point may comprise a bolt hole or aperture. In some embodiments, multiple mounting points are provided on the joists, mounting bar, and/or frame.

The frame may be configured such that the at least one mounting point can support a loading of up to 1 tonne. In some embodiments, the frame may be configured to support up to one tonne across multiple mounting points.

The frame may comprise at least one beam. The at least one beam may extend from a first to a second intermodal container in use. The at least one beam may form part of a ceiling level of the roof module. The at least one beam may form part of a truss. The beam may comprise a first C-channel element reinforced with a second C-channel element. In some embodiments, the beam may comprises one or more further stiffening or strengthening portions.

The frame may further comprise wire tensioners. The wire tensioners may extend across the frame and provide additional strength and rigidity e.g. by holding the frame in tension.

According to a second aspect of the invention, there is provided a mounting system for fitness equipment. The mounting system may comprise a first and second elongate support. The first and second elongate supports may each comprise a connecting portion at each end thereof e.g. for connecting to a corner fixture of an intermodal container. The mounting system may comprise a mounting rail. The mounting rail may be connectable between the first and second elongate supports. The mounting rail may comprise at least one mounting point therein e.g. for connecting an item of fitness equipment thereto.

The first and second elongate support may comprise posts. The post may be configured to be connectable to an intermodal container substantially vertically in use. The posts may comprise a plurality of formations for connecting with the mounting rail. The plurality of formations may be configured such that the mounting rail is connectable to the first and second elongate supports in multiple positions e.g. to vary the height or position of the mounting rail.

In an alternative series of embodiments, the first and second elongate supports may comprise support rails, configured to extend substantially horizontally between corner fixtures of an intermodal container in use. In such embodiments, the mounting rail may extend substantially vertically between the first and second support rails.

The first and second elongate supports may further comprise at least one mounting points for connecting an item of fitness equipment thereto.

The mounting rail may comprise a first rail portion and a second rail portion. The first and second rail portions may be connectable to each other via a rail connector. The rail connector may comprise a sleeve into which an end of the first and second rail portions may be locatable. The rail connector may further comprise one or more mechanical fasteners to secure the first and second rail portions thereto. In some embodiments, the sleeve may be integrally formed with one of the first or second rail portions. In some embodiments, the first and second rail portions are configured to be telescopic.

The rail may be provided with a brace. The brace may be configured to bear upon the surface of said intermodal container in use. The brace may be connectable to the rail via one or more of the mounting points on the rail. The brace may comprise an arm extending from the rail. The arm may be provided with a bracing end configured to bear against the surface of said intermodal container. The bracing end may be formed from a rubber or plastics material. In some embodiments, multiple braces may be provided. The mounting system may further comprise one or more item of fitness equipment. The one or more items of fitness equipment may be connectable to the rail and/or the elongate supports. The one or more items of fitness equipment comprise one or more from the group consisting of: pull-up bars, dip bars, barbell racks, weight racks, power cages and half-racks, medicine ball targets, ladders, ropes, climbing frames, punch bags, mounting points for suspension training and gymnastic equipment, landmine barbells and hinges, The Grappler™ and other rope pull systems, step-up and platform attachments, cable pulley systems, cardio equipment, storage racks, benches, safety arms, and any other suitable items of fitness equipment.

According to a third aspect of the invention, there is provided a building structure comprising a roof module as described herein and at least one intermodal container. The at least one connector of the roof module is connected to a corner fixture of the intermodal container. The building structure may be a temporary or semi-permanent structure.

The roof module may extend from a first to a second intermodal container. The roof module may extend over the first and second intermodal containers. The roof module may be only supported by the intermodal containers. The building structure may comprise a flooring structure positioned beneath the roof module and adjacent to the at least one intermodal container. The building structure may comprise one or more wall portions configured to extend from the roof module to ground level and/or enclose the floor structure. The one or more wall portions may comprise a curtain connected to a beam of the frame. The building structure may comprise one or more levelling devices for levelling the at least one intermodal containers. The one or more levelling devices may comprise container jacks.

The building structure may further comprise the mounting system as described herein.

According to a fourth aspect of the invention, there is provided a method of forming a building structure. The method may comprise providing at least one intermodal container and providing a roof module as described herein. The method may comprises positioning the roof module onto the intermodal container, such that the at least one connector of the roof module is aligned with the corner fixture of the intermodal container. The method may comprise connecting the connector to the corner fixture.

Connecting the connector to the corner fixture comprises may comprise connecting the two parts using a mechanical connector e.g. a bolt. The method may comprise using a first mechanical fastener to connect a first connection portion of the connector to a first side of the corner casting. The method may comprise using a second mechanical fastener to connect a second connection portion of the connector to a second side of the corner casting. The method may comprise repeating the connection step for each connector of the roof module.

The method may further comprise connecting a mounting system as described herein to the at least one intermodal container. The method may comprise connecting a first and second elongate support to the intermodal container. The method may comprise connecting a mounting rail to the first and second elongate supports. The method may further comprise connecting at least one brace to the mounting rail. The method may comprise connecting one or more items of fitness equipment to the mounting rail and/or the elongate supports.

Brief Description of the Figures

The invention will now be described with reference to the following figures, wherein:

Figure 1 is a perspective view of a building structure;

Figure 2 is a perspective view of a partially assembled building module;

Figure 3 is an end-on view of a building module;

Figure 4 is a perspective view of a connector;

Figure 5 is a perspective view of a connector;

Figure 6 is a cross section through a beam;

Figures 7 and 8 are perspective views of mechanical fasteners;

Figure 9 is a perspective view of a mounting system; and

Figure 10 is a front-on view of a mounting system. Specific Description

Turning now to Figure 1, there is shown a building structure 1. The building structure 1 is formed from two series of aligned intermodal containers 11, which are connected by a series of roof modules 13. Each pair of intermodal containers 11 and the corresponding roof modules 13 which extends between then form a building module 20, as shown in Figure 2. Between the series of intermodal containers 11 is provided a flooring structure 15. The building structure 1 thus forms a suitable building for installing fitness equipment, such that the structure forms a semi-permanent gym. The building structure 1 is open at each end, although wall panels or curtains (not shown) can be provided and installed in order to completely enclose the interior of the building structure 1.

Turning now to Figures 2 and 3, the building module 20 will be described, wherein the roof surface 13a has been removed for ease of illustration. The building module 20 comprises a pair of intermodal containers 11 spaced apart and connected by a roof module 13 which spans the space between the two containers. The roof module 13 is a pitched roof, with the apex located centrally between the intermodal containers 11.

The roof module 13 is formed from a frame 25 formed from a pair of roof trusses 27, each trusses formed from a beam 29, a pair of rafters 31, a king post 32, side posts 33, and multiple struts 35. The trusses 27 are joined to each other via purlins 37 and joists 39 and via the intermodal containers 11. The elements of the frame are connected to each other via mechanical fasteners, such as bolts or rivets. The rafters 31 and purlins 37 form an upper surface to which the roof surface (13a, Figure 1) can be connected. Typically the roof surface comprises corrugated metal sheets connected to the rafters and purlins by mechanical fasteners (not shown) such as bolts. The beams 29 and joists 39 form a ceiling level within the building module 20, which would typically be left open such that the frame is visible from underneath. The frame has a series of wires 38 connecting the apex of the pitched roof frame to various points on the opposite truss 27. The wires 38 are tensioned in order to place the frame under tension and thereby increase its strength.

The roof module 13 is connected to the containers 11 by connectors 21 , 23 provided at each corner of the frame. The trusses 27 define a length direction, and the connectors 21 are spaced inwards from the corners of the frame in the length direction by a distance equivalent to the width of an intermodal container, such that the connectors 21, 23 can connect with each of the corner fixtures 12 on the upper surface of the intermodal containers 11.

The building module can be provided in a range of sizes, with a span, i.e. the distance between opposing intermodal containers 11 in the length direction, of up to 20 metres. Smaller structures can be accommodated by using shorter trusses. As shown in Figure 1 , the building modules 20 can be connected together in series to provide a building structure 1 of essentially any width i.e. in the direction parallel with the intermodal containers. To increase the width, more intermodal containers and roof modules are connected onto an end of the building structure. The roof surface can then be joined with the roof surface of an adjacent roof module to form a single continuous roof surface.

Turning now to Figure 6, there is shown a cross section through one of the beams 29. The beams 29 comprise a first beam portion 29a having a C-shape cross-section, and a second beam portion 29b also having a C-shape cross-section, nested within the first beam portion 29a. The combined beam portions provide a significantly increased strength and rigidity over a single beam portion and thus produces a stronger and stiffer roof module. In many embodiments, any of the rafters 31 , king post 32 and side posts 33 may have the same structure. In some embodiments (not shown) further stiffening portions may be provided in any of the beams, rafters or posts.

Turning now to Figures 4 and 5, there is shown a close up of the connectors 21 , 23 in isolation from the rest of the frame of Figures 2 and 3. The connectors 21 , 23 have first connection portions 211 , 231 and second connection portions 212, 232. Each of the first and second connection portions 211, 231, 212, 232 are flat plates having an aperture 214 therethrough. The first and second connection portions 211, 231 , 212, 232 extend at right angles to each other, such that they form a right angled corner 215, 235 between the two portions. A third connection portion 213 extends perpendicularly to the first and second connection portions, and is provided with a series of holes therein for fixing the third connection portion to the beam 29 and/or rafters 31 of the frame. In use, the angled corners 215, 235 are located over the corner fixtures 12 of the intermodal containers 11 such that the first and second connection portions 211, 231 , 212, 232 are positioned adjacent to two perpendicular surfaces of the corner fixture 12. A mechanical fastener (not shown) can then be inserted through each of the apertures 214 and fastened in order to secure the connectors 21, 23 and thus the roof module 13 in position. By providing a right angled corner with two connection portions which are connected by two faces of the corner fixture 12, a far more secure connection can be achieved without requiring drilling through the skin of the intermodal container 11. Any wind loading forces exerted on the roof module 13 are better distributed to the building structure 1 rather than localised through a single connection of the roof module and the containers. In some cases, high forces applied to the roof module 13 cause a twisting force to be applied through the connection of the roof module and the corner fixture. Similarly, by connecting to both sides of the intermodal container (e.g. the ‘internal’ and ‘external’ sides), the rigidity of the containers themselves provides additional strength and rigidity to the roof module in use. The connectors 21, 23 thus form a roof which is better able to withstand such forces by distributing the force through the intermodal containers.

Turning now to Figures 7 and 8, there are shown two forms of mechanical fastener 22, 24 which form part of the connectors 21, 23. The first mechanical fastener 22 comprises a bolt 221, having a head 222 and a bracket 223 at a first end, and a nut 224 and washer 225 at a second end. The bracket 223 has a recess on its rear face formed by a pair of walls 226 between which the bolt head 222 is received. The recess has a width configured to closely match the width of the bolt head 222 and thus prevent rotation of the bolt 221 relative to the bracket 223. On the front face of the bracket 223 is a projection 227 and flanged wings 228, joined by a shoulder 229. In use the head 222 and bracket 223 of the mechanical fastener are inserted into the oval shaped hole in the corner fixture of the intermodal container (not shown) and rotated through 90° such that the flanged wings 228 bear upon the inside surface of the corner fixture. The projection 227 thus extends into the oval shaped hole such that the shoulder bears upon the edges of the hole in the corner fixture. The bracket 223 and bolt 221 are thus prevent from rotating relative to the corner fixture. The connector 21, 23 is lowered over the corner fixture such that the shaft of the bolt 221 extends through the aperture 214 of the connector 21, 23, and the washer 225 and nut 224 are threaded onto the bolt 221 and tightened against the first connection portion 211 , 231 in order to secure the roof module to the intermodal container.

In Figure 8, a variant of the mechanical fastener is shown. The mechanical fastener 24 also comprises a bolt 241 having a head 242 at a first end, and a bracket 243 at a second end. The bracket 243 has a first block 247 equivalent to the projection 227, and a second block 248 equivalent to the flanged wings 228. The first block 247 is shaped to fill the oval-shaped hole within the corner fixture (not shown) and the second block bears upon the internal surface of the corner fixture of the intermodal container. In use, the bracket 243 is located within the corner fixture such that the first block 246 fills the oval-shaped hole, the connector 21 , 23 is located onto the corner fixture, and the bolt is passed through the aperture 214 in the second connection portion 212, 232 of the connector 21 , 23. The bolt 241 is threaded into the bracket 243 and tightened to secure the roof module to the intermodal container.

Typically, the mechanical fastener 22 is intended for use with the upper surface of the corner fixture, and correspondingly, the first connection portions 211, 231 of the connectors 21, 23. The mechanical fastener 24 is intended for use with the side surface of the corner fixture, and correspondingly, the second connection portions 212, 232 of the connectors 21 , 23. This arrangement is particularly desirable given the space constraint within the corner fixture, although it would be understood that pairs of the same mechanical fasteners 22, 24 may be used in some cases.

Turning now to Figures 8 and 9, there are shown mounting systems 100, 120. Mounting system 120 is a variation of mounting system 100, whereby descriptions for like parts will not be repeated.

The mounting system 100 is formed from first and second elongate supports in the form of posts 102, 104. The posts 102, 104 are connected to the corner fixtures 12 of an intermodal container 11 via mechanical fasteners, such as bolts.

Spanning the width of the intermodal container 11 between the posts 102, 104 is a mounting rail 106. Each of the posts 102, 104 are provided with a series of formations 106 for connecting to the mounting rail 110. In the embodiment shown, the formations are a series of holes spaced along the length of the posts. The mounting rail 106 is provided with a bracket 107 at each end thereof, which corresponding hole therethrough, such that the mounting rail 106 can easily be fastened to the posts 102, 104 using bolts or other mechanical fasteners. The series of holes in the posts 102, 104 permits the mounting rail to be fixed at a range of different heights.

In the embodiment shown, a pair of mounting rails 110 span between the posts 102, 104. Each mounting rail 110 is formed from a first rail portion 111 and a second rail portion 112, and connected to each other via a rail connector 113. The rail connector has a pair of sleeves which receive an end of each of the first and second rail portions 111 , 112, and is secured by further mechanical fasteners such as bolts. The two sleeves are connected by a spacer which ensures the two mounting rails 110 are held parallel to each other. By providing the rails in rail portions which can be assembled, the weight and length of each rail portion is made more manageable and installation is simplified.

The mounting rails 110 are each provided with a series of mounting points 114 to which items of fitness equipment 115 can be mounted. Preferably, the mounting points 114 and the formations 106 are the same, thereby allowing items of fitness equipment to also be connected to the posts 102, 104 as needed.

In Figure 10, the mounting system 120 is substantially the same, except that two pairs of the mounting rails 110 are provided. The additional mounting rails provide additional attachments points for further fitness equipment, such as power racks 116. As shown, the power racks 116 extend away from the mounting rails 110, and have feet 117 which bear upon the floor surface 15 to provide additional support. The system thus provides a highly configurable system for mounting items of fitness equipment, and which can be fully supported by the mounting system, such as the platforms 115, or partially mounted and floor supported, such as the power racks 116.

In use, the mounting system 100, 120 can be fitted to either the internal or external side of an intermodal container 11 , thus provide a wide array of fitness equipment both within and on the exterior of the building structure 1.