A transportable building including a roof structure for stacking of multiple buildings

FIELD OF THE INVENTION

The present invention relates to a transportable building for use in portable camps and, in particular, to a transportable building have a roof structure which allows for a further transportable building to be stacked there above.

BACKGROUND OF THE INVENTION

Camps have been used for many years to provide shelter and accommodation especially in remote areas. This is especially so in the case of remote camps that are assembled using a number of transportable buildings, some of the buildings used as sleeping quarters, others as the kitchen and dining room facility and others still as recreational areas. It is not uncommon for a camp to consist of sixty to eighty buildings that can accommodate several hundred people.

These camps are completely self-contained in that the transportable buildings provide all of the facilities for a small remote community that may be needed in a particular area. Accordingly these camps include all of the modern day facilities such as electrical power, water, sewerage, and communication. They therefore typically also include their own power generation systems, water distribution systems, sewerage treatment plants, and communication facilities such as satellite dishes. The camps typically require a considerable amount of skill, time, and effort to assemble and commission. Once constructed, these camps can however provide accommodation indefinitely if the infrastructure is maintained.

In some instances the camps have to be portable or mobile. For example, during construction of infrastructure across a vast area, such as roads or pipelines supplying water or gas, a particular location for a camp housing the construction workers, may only be viable for several weeks or months. As the pipeline is progressively constructed, there is a balance between the economic cost of the travel time of workers housed in the camp to the current work site and time spent constructing the actual pipeline. It is therefore accepted in the industry that if the travel time between a camp and the work location is more than an hour, a new camp has to be constructed that is closer to the work location. At that time, a new camp is therefore constructed one hour ahead of the current construction location or generally up to several hundred kilometres away from the existing camp.

Typically, each building in a portable camp will include the same predetermined layout and structure. For example, in existing transportable buildings manufactured by the Applicant, the roof structures typically include the same structural components as that of the side walls of the building, that is, they comprise basic framework, an internal lining and external sheeting. For this reason, it has not in the past been conceived that two or perhaps more transportable buildings could be stacked one above the

other. It is envisaged that the lower building would simply buckle under the weight of the upper building and its contents.

The present inventor is the owner of Australian Letters Patent No. 2003227102, directed towards an improved transportable building chassis and its ability to be easily lifted and transported using a device such as a forklift. This enables the buildings to be transported with ease, and makes commissioning and decommissioning of camps a much more fast and efficient process.

Although one could simply manufacture buildings which have a structure capable of withstanding the weight of a further building there above, in the portable camp industry where time and costs associated with the construction and transportation of buildings and equipment is of importance, permanent structures are unsuitable. There is therefore a need for a building, such as the transportable building disclosed in the abovementioned Letters patent, which includes all of the features that are required of a building within a portable camp, but which is also robust enough to support a further transportable building there above. The skilled addressee would realise that in providing stackable buildings of this sort, a portable camp is capable to accommodating more people than hitherto known camps within a smaller surface area.

A further potential problem that has been envisaged by the present inventor is in the supply of utilities such as electricity and gas to two stacked buildings. The inventor has recognised the need for a more efficient method of "wiring up" two stacked buildings.

It is an object of the present invention to overcome at least some of the abovementioned problems or provide the public with a useful alternative.

It is a further object of the present invention to provide a transportable building including a roof structure having a frame that is capable of supporting a second transportable building there above, the roof structure further housing utility supply means to one or both of the stacked buildings, as well as insulation material.

SUMMARY OF THE INVENTION

Therefore in one form of the invention there is proposed a transportable building characterised by a roof structure including load supporting structural elements configured to support a further transportable building there above.

Preferably said roof structure is further configured to accommodate utility supply means to at least one of said stacked buildings.

In preference said building is of a rectangular construction, and said load supporting structural components are in the form of two spaced apart girders disposed parallel to a longitudinal axis of said roof structure, each girder having respective front and rear ends and a top and a bottom flange connected by a web.

In preference said roof structure further includes a front member and a rear member connected normal to and across the respective front and rear ends of said girders.

Preferably said roof structure further includes a plurality of elongate beams or purlins extending laterally between said girders.

Preferably said elongate beams are fixed at their highest position at the centre of the girders, and at their lowest positions at the ends of the girders in the further stacked building, to thereby ensure that roofing panels fixed above said purlins are slightly concave to facilitate water run-off.

Advantageously, said transportable building includes a base chassis having two spaced apart load bearing beams, and a pair of longitudinally spaced apart and laterally extending channels adapted to be engaged by forks of a forklift for lifting said transportable building.

Preferably said roof structure further includes a ceiling, said ceiling including a plurality of apertures located at predetermined positions according to the location of utility supply destinations inside said transportable building, each aperture adapted to receive utility supply means corresponding with the utility supply means destination.

Preferably said roof structure includes a floor surface of said further building mounted above said girders, said floor including a plurality of apertures located at predetermined positions according to the location of utility supply destinations inside said further transportable building, each aperture adapted to receive utility supply means corresponding with the utility supply means destination.

In preference each aperture is positioned as close as possible to each corresponding utility supply destination.

Preferably when said utility supply means is in the form of an electrical cable, said utility supply destination is a corresponding electrical appliance inside said transportable building.

Preferably said electrical appliance is in the form of a light, a light switch, or a power outlet.

Preferably when said utility supply means is in the form of a gas conduit, said utility supply destination is a corresponding gas appliance inside said transportable building.

In preference said gas appliance is in the form of an air conditioner, a gas fired oven, or a freezer.

Preferably said ceiling is fixed between said girders using a chemical bonding foam.

In preference said floor is fixed between said girders using a chemical bonding foam.

Preferably said chemical bonding foam is also insulating foam.

In preference utility supply housings extend from said apertures to said destinations along the internal walls and ceiling of said transportable buildings, said housings adapted to house and conceal the utility supply means.

In a further form of the invention there is proposed a portable camp including a plurality of stacked transportable buildings as described above.

In a still further form of the invention there is proposed a modular building characterised by: a first transportable building of substantially rectangular construction including a roof structure having two spaced apart load supporting girders disposed parallel to a longitudinal axis of said roof structure, each girder having respective front and rear ends and a top and a bottom flange connected by a web, front and rear members connected normal to and across the respective front and rear ends of said girders, and a plurality of elongate beams extending laterally between said girders; a second transportable building of substantially rectangular construction including a roof structure having two spaced apart girders disposed parallel to a longitudinal axis of said roof structure, each girder having respective front and rear ends and a top and a bottom flange connected by a web, front and rear members connected normal to and across the respective front and rear ends of said girders, and a plurality of elongate beams extending laterally between said girders; wherein said second transportable building is stacked above the roof structure of the first transportable building, said second transportable building being supported by said first building load supporting girders.

Preferably said first and second buildings include a base chassis, side walls and at least one access door on said side wall.

In preference said first transportable building includes a walkway outside said access doors, and said second transportable building includes a balcony spaced above said walkway.

In preference said balcony is accessible from said walkway using a connecting staircase.

In a yet further form of the invention there is proposed a portable camp including a plurality of modular buildings as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention.

In the drawings;

Figure 1 illustrates a transportable building in accordance with the present invention;

Figures 2a-2c illustrate from a front, top and side view an elevated platform which may be used in the construction of the roof structure forming part of the transportable building of Figure 1;

Figure 3 illustrates a perspective view of the elevated platform of Figure 2;

Figure 4 illustrates a top view, following the first stage of construction, of the frame and ceiling panels of the building roof structure of Figure 1;

Figure 5 illustrates a perspective view of Figure 4;

Figure 6 illustrates a top view, following the second stage of construction, of the frame and ceiling panels of the building roof structure, the ceiling panels including apertures for accommodated electricity cables and the like;

Figure 7 illustrates a perspective view of Figure 6;

Figure 8 illustrates a top view, during the third stage of construction, of the frame and ceiling panels of the building roof structure having foam insulation material sprayed between each frame member and the adjacent ceiling panels;

Figure 9 illustrates a perspective view, following the fourth stage of construction, of the frame and ceiling panels of the building roof structure after foam has been sprayed above the entire ceiling area;

Figure 10 illustrates a top view, during the final stage of construction, of the frame, ceiling panels and foam insulation of the building roof structure being the lengthwise laying of corrugated roofing panels above the frames;

Figure 1 1 illustrates a perspective view of a fully constructed building roof structure; and

Figure 12 illustrates a modular building including two transportable buildings stacked one above the other in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

Referring to Figure 1, there is illustrated a transportable building 10 in accordance with the present invention. The transportable building includes a roof structure 12, a floor 14, parallel ends 16 and 18, and longitudinal side walls 20 and 22, and doors 24 located on side wall 20. Of course, the geometry of the building 10 may vary and it is not intended to limit the present invention to the same exact type of building.

The building 10 is mounted on a chassis 26 that preferably includes channels 28 allowing each building to be handled by a forklift (not shown). The building 10 shown is mounted above stacked and spaced apart footing members 30, however, leg supports (not shown) could equally well be provided at the corners of the chassis to position the buildings on a site. Furthermore, the leg supports could include self-levelling means.

Figures 2-11 illustrate a means by which the roof structure 12 of the transportable building 10 can be constructed as well as the steps of construction. Two stacked transportable buildings are illustrated in Figure 12, where it is evident that the primary structure for supporting the chassis 26 of the second building there above is the roof structure 12 of the building 10 below. Although Figure 12 shows the upper building being lowered onto the building using a crane (not shown), a forklift (not shown) is the preferred method of transporting and lifting the buildings in place, as mentioned above.

The roof 12 comprises two longitudinal, C-section girders 32 and 34 which are inwardly directed, and a plurality of equally spaced purlins 36 extending between the girders 32 and 34. The purlins 36 are positioned in a diagonal or curved manner along the length of the girders such that the purlins are at their highest position in the middle, and at their lowest positions towards the ends of the girders 32 and 34. The skilled addressee would realise that because roof sheeting 38 is adapted to be fixed directly above the purlins 36, or at least on the purlins of the uppermost building 10, they need to be positioned like so to facilitate water run-off from the roof sheeting. There are also two vertically aligned end purlins 40 and 42, and 44 and 46 positioned one above the other at the ends of the girders, which cap the roof structure 12.

Forming part of the roof structure is a ceiling 48, the bottom surface of which is flush with the bottom surface of the C-section girders 32 and 34 which line opposed sides of the ceiling. Effectively, the ceiling 48 extends between the C-section girders 32 and 34. As described in more detail below,

polyurethane foam 50 is sprayed between the ceiling 48 and frame members, not only for insulation purposes, but also as a means of binding the ceiling and the surrounding frame member, including with the girders 32 and 34, without the need for mechanical fasteners such as screws, bolts and the like.

As mentioned in the preamble of the invention, transportable buildings constructed on a large scale, for example for use in a portable camp, are typically identical and constructed according to a predetermined layout. This obviously reduces time and cost during construction, and during commissioning and decommissioning of camps. For example, the position of the lights, the position of the air conditioner, and the position of the power outlets on the walls are typically all predetermined.

The ceiling 48 of the roof structure 12 is also constructed in accordance with this predetermined layout in that during its construction, apertures 52 are drilled where each electrical or gas appliance is located so as to accommodate cables and conduits 53 for supplying such appliances. For example, there may be an aperture 52 located at the centre of the ceiling 48 for accommodating wiring corresponding with the main light. Similarly, there may be apertures 52 in the ceiling 48 adjacent the walls for accommodating wiring which corresponds with power outlets on the side wall or light switches. Where there is an air conditioner (not shown) mounted on a wall of the building, apertures 52 would be present in the ceiling 48 at the precise position there above to accommodate the electrical wiring and gas conduits.

When two buildings are stacked one above the other, that is, when the chassis 26 of a first building is lowered on top of the roof structure 12 of a second building 10, as shown in Figure 12, the upper building could in fact also be wired using the roof structure 12 of the lower building. In such circumstances, the floor of the upper building would include strategically placed apertures (not shown), similar to those present in the ceiling 48, for accommodating cables. Obviously the floor apertures would be restricted to sides of the building, not the centre where occupants walk.

Therefore, only the lower of the stacked buildings requires a roof structure 12, and the top building could be a conventional transportable building. Alternatively, both buildings include the roof structure 12 and are pre-wired independently, or only the lower roof 10 is pre-wired for both buildings, and roof structure 12 is used in the upper building for insulation purposes only. The present invention is not intended to be limited to any one of these configurations.

In the embodiment shown in Figures 2-3, a construction platform 54 is used in the manufacture of such a roof structure. The platform 54 is made up of a horizontal frame 56 comprising various structural members 58 supported above legs 60, the legs 60 having rollers 62 at lower ends thereof for facilitating movement of the platform 54. Supported above the frame 56 is a horizontal support surface 64, preferably made of wood, above which the roof structure 12 is to be constructed. It is to be understood that although

the platform 54 is the preferred apparatus used to manufacture the roof structure 12, the present invention is not intended to be limited to only this means of manufacture.

The horizontal surface 64 is preferably marked up according to the size, shape and utility layout of the building(s). For example, the width and length of the roof structure 12 could be marked on the top surface using an appropriate marking means. There is also a plurality of pre-drilled guide holes 66 extending through surface 64 according to the pre-determined building layout. In particular, the guide holes 66 are positioned in correspondence with the position of various electrical/gas items inside the building(s) such as lights, power outlets, switches and air conditioning systems.

Therefore, the various steps of construction are outlined as follows:

1) As mentioned, the surface 64 is preferably marked up so that the width of the building is known and the assembler can simply place the girders 32 and 34 in their correct spaced apart locations on the surface. In preference, the longitudinal girder 34 is placed right up against one longitudinal side of the platform 54 while the other girder 32 will typically be placed inwards of the other longitudinal side, the surface 64 being wider on that side so as to also provide walking space alongside the roof structure during construction. L-shaped brackets 68 can be used to abut against the outer side of girder 32 so as to maintain it in position throughout the construction process.

As also mentioned, two vertically disposed end purlins are mounted between the girders 32 and 34 at ends thereof. The two end purlins are preferably mounted to the girders using mechanical fastening means such as a nut and bolt connections.

2) The next step in the process is the laying down of the ceiling 48. The ceiling 48 is preferably made of strong, slightly flexible, waterproof material. Such material is typically shipped in panels 70 and so rather than having a single ceiling structure, the ceiling will typically be made up of a plurality of connecting panels 70. The plurality of panels 70 making up the ceiling 48 can be seen clearly in Figure 4. It is to be understood that a large single panel could equally well be used, although this is not practical as the surface area of the ceiling is quite large.

As mentioned earlier, the ceiling panels 70 are not bolted to the girders or end purlins, they are simply placed above surface 64 so that they are located inside the respective frame members. Separating each panel are plastic joining strips (not shown) which serve to connect adjacent panels and thereby fill the gap there between and offer a more pleasing appearance from inside the room. Such strips are well known in the art.

Therefore at the end of this step, the basic rectangular frame of the roof structure 12 is established, and the ceiling panels 70 are laid in place and coupled via joining strips.

3) Once the ceiling panels 70 are in place, the apertures 52 which accommodate the various cables

53 need to be drilled into the ceiling 48. This is achieved by drilling upwards through the pre- drilled guide holes 66 present in the platform surface 64 mentioned earlier. Those skilled in the art would realise that in doing so, the same guide holes 66 that are present in the platform surface 64, will be formed in the ceiling 48. This is the reason the platform 54 is elevated, so that there is access to beneath the structure for drilling the ceiling apertures 52.

Mounted on one side of the platform 54, there is a black board 72 supported by posts 73. The purpose of the black board 72 is to mark out which electrical appliance, for example, corresponds with a particular aperture 52 in the ceiling 48. For example, a light switch (not shown) located on the near side of the building 10 could be marked out on the bottom of the blackboard 72 in the relevant longitudinal position, whilst a power outlet (not shown) located at the same longitudinal position but on the opposite wall of the building 10 could be marked out on the top of the blackboard 72, and so on. It is then easier for an electrician or other worker to wire up the roof structure 12, and further roof structures there after, using the same platform 54. Where the roof structure 12 is used to accommodate utility supply to both buildings, the blackboard can also be used accordingly.

4) The next step is wiring up the roof structure 12 which involves inserting the plurality of electrical cables and gas conduits 53 through one end of the roof (preferably below the lower of the two end purlins 40 and 42, or 44 and 46, through to the respective apertures 52 in the ceiling 48. Should the roof structure 12 be wired to also supply a second building stacked there above, then these wires could be made to simply extend to the correct position ready for insertion through floor apertures (not shown) in the upper building, during their assembly. It is therefore possible for all wiring and cables required to supply two stacked buildings are run through the one roof structure 12 and into the corresponding ceiling/floor apertures 52.

As shown in Figure 7, approximately 2 metres of cabling is fed through each ceiling aperture 52 to allow for it to extend to a corresponding appliance. Obviously, any length of cable could be fed through depending on the distance of the appliance from the ceiling 48, for example, more cabling would be required for say the central light of the upper building which will require the cable to extend up along the side wall as well as halfway along the ceiling of the upper building 10. A central light in the lower building may only require a small length of cable, whilst a power outlet located at the bottom of the lower building may require 2-3 metres of cable.

5) Once the ceiling 48 is laid, the purlins 36 which extend between the girders 32 and 34 may be connected. This step could have been undertaken prior to steps (2), (3) or (4) above, however, in preference this step is completed afterwards so that the purlins do not form an obstruction to the person(s) laying the ceiling and wiring up the roof. The purlins 36 are simply bolted at their opposed ends to the girders 32 and 34 using known mechanical fastening means, and as mentioned earlier, are raised toward the centre of the girders and lowered towards the ends to facilitate rain water run-off.

Therefore at the end of this step, the complete frame of the roof structure 12 is established, as is the ceiling 48. Furthermore, the roof structure 12 is completely wired for one or both of the buildings. Those skilled in the art would realise that such a roof structure includes good strength characteristics when compared to hitherto known roof structures of this kind, and this is what enables the transportable building of the present invention to support a further building there above.

6) In order to now bind the ceiling 48 with the surrounding roof frame members 32, 34, 36, 42 and

44, and to secure the network of cables and conduits 53 in place, polyurethane foam 50 is sprayed above the ceiling 48. The foam 50 has been developed such that when it is exposed to air it hardens to form a rigid insulation material for the roof 12. The foam also has exceptional chemical bonding properties so that foam 40 which contacts both the ceiling 48 and various frame members, bonds the two structures together, hence why no mechanical fastening means are required to secure the ceiling in place.

In preference, the foam is firstly sprayed between the ceiling 48 and each of the purlins/girders in order to ensure that the ceiling 48 is securely fixed, as shown in Figure 8. Then once this is completed, the remainder of the ceiling 48 can be sprayed until an adequate amount is present for the purpose of insulating the building 10 as well as securing the network of wiring and conduits 53 above the ceiling 48 in their designated positions.

Where there will be roof panels secured to the purlins, for example in the roof structure of an uppermost stacked building, then obviously the foam 50 should not exceed the height of the purlins. Where the roof structure 12 is intended as a supporting structure for a further building there above, then foam could be used to fill the entire area there between.

7) The final step in constructing the roof structure 12 is the laying and bolting down of the longitudinal roofing panels 38. This need only be done for the uppermost buildings, however as shown in Figure 12, they could also be used in the lower buildings. In the embodiment shown, the

roofing panels 38 are corrugated roofing panels which extend the entire length of the building structure, however, other configurations are possible.

The panels 38 are preferably laid starting at one side of the structure 12 and finishing on the other, with each panel being bolted down at spaced apart positions along the transverse purlins

36. As mentioned, the purlins are at their highest position in the middle portion of the girders 52 and 54, and extend in between the two end purlins 40 and 42 on one side, and 44 and 46 on the other. The panels 38 are preferably fixed above the lower of the two end purlin pairs 42 and 44.

In a further embodiment, the roof structure 12 could be manufactured to already include the floor 14 of a building adapted to be stacked there above, mounted above the girders of the roof structure 12. In such circumstances, the upper building would be manufactured with only side walls and a roof, as well as connection means to the supporting structure 12 below which includes the floor 14. Again, such a roof structure 12 would not require roof panels.

It is to be understood that the present invention is not intended to be limited to the location of the guide holes 66, or the number/arrangement of cables and conduits 53, to that which is illustrated in the drawings. These are shown by way of example only. For example, there may be four separate sleeping quarters in any one transportable building 10, or eight sleeping quarters in two stacked buildings. In such circumstances, the network of cables/conduits 53 and the location of the apertures 52 in the ceiling 48 and floor 14 would be a lot more complex compared to that which is shown in Figure 6 for example.

It is to be further understood that the roof structure could equally house other supply items such as water and sewage pipes and is not intended to be limited to only electricity and gas supply only. For example, the roof structure of a lower building could well include pipework for toilets and showers in the buildin *sg s ^■ tacked there above.

It is envisaged that all parts used in the roof structure 12 will be manufactured specifically to ensure fast and efficient construction. For example, rather than drilling the apertures 52 by the means described above, each individual ceiling panel 70 or building floor 14 could be pre-manufactured so that they include pre-drilled apertures 52. Further still, each panel 70 could be numbered according to their position on the roof for ease of installation. The skilled addressee would realise the benefits in simply having to lay down the pre-drilled panels in numbered order between the frame members. Similarly, the girders 32 and 34, and purlins 36, could include pre-drilled apertures for accommodating bolts, for example, at the various positions where the structural members are intended to be connected.

The advantages of the transportable building 10 of the present invention should now be evident. During commissioning of a camp, multiple stacked buildings 10 can be quickly and efficiently erected by forklift operators able to transport and stack buildings one above the other. The roof structure 12 of the

building is of a sufficient strength to support the further building thereabove, as well as its contents and occupants. Not only does the roof structure 12 enable stacking of buildings, it is also capable of housing utility supply means for one or both buildings, as well as insulating material. Then, once the various structures are joined, other accessories such as end and side cappings (not shown), staircases (now shown) and balconies (not shown) can be easily erected. For example, the roof structure frame members could include anchor points for connecting the frame of a walkway/balcony thereto, as well as a verandah between rows of stacked buildings. It is envisaged that a camp which utilises the transportable buildings 10 of the present invention can house at least double the amount of occupants as a standard camp of the same surface area.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.

In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further features in various embodiments of the invention.