The present invention relates to a prefabricated shell for forming a utility room in a building and particularly but not exclusively for forming a utility room in a block of apartments or flats with shared services.

BACKGROUND TO THE INVENTION

In residential construction projects, it is necessary to install utilities such as heating, ventilation and electrical power. This requires installation of a number of utility units such as a water heating unit, a distribution board for the electricity supply, a mechanical ventilation unit, and sometimes appliances such as washing machines or tumble driers. The units and appliances must be connected to utilities conduits such as electrical power cables, ventilation ducts, gas supply and water flow and return pipes.

In larger projects such as apartment buildings, it may be necessary to repeat a number of identical installations. It has been found that significant cost and time savings can be obtained by providing prefabricated utilities panels, incorporating some or all of the above units, appliances and connections fixed to a frame or board. This allows a significant amount of standardised work to be performed off-site, simplifying the overall construction process.

Such panels are typically installed in a dedicated utilities cupboard or room, separated from living spaces by a door. This is because the necessary connectors and conduits are generally considered unsightly and undesirable in a domestic environment.

A problem with this approach is that the dedicated cupboard or room cannot generally be used for any other purpose. It may be possible to use the space for storage, for example of ironing boards or vacuum cleaners, but this can limit access to the utilities units and be inconvenient.

This problem is particularly acute in urban residential developments, where the available space is often severely limited.

A further problem of prior art utilities panels is that they are typically large compared to the size of a door, making them difficult to manoeuvre and install. A prefabricated utility station proposed in the applicant’s co-pending patent application GB 1806324.8 comprises a substantially U-shaped outer casing having a first side, a second side spaced from the first side, and a back side perpendicular to the first and second sides and joined to each of the first and second sides. A substantially U- shaped inner wall is disposed within the outer casing and joined to a front edge of each of the first and second sides. At least one utility unit is provided and at least one conduit is connected to the utility unit for supplying the utility unit with a utility. The utility unit is mounted to a rear side of the inner wall, disposed between the inner wall and the outer casing, and the conduit extends from the utility unit to the outer casing, for connection to a utility outlet of a building.

This prefabricated utility station provides a unit that can be inserted into an appropriately sized void to provide a finished utility area that is suitable for a domestic environment.

In particular, the outer casing abuts the walls of the void and provides structural integrity. The space defined between the inner wall and the outer casing houses the necessary connectors, pipes and cables, referred to generally as conduits. The conduits are hidden from view by the inner wall so that the prefabricated utility station presents an acceptable aspect for a domestic space.

Although this prefabricated utility station has been found to be extremely effective, it is relatively complex to build, requiring a relatively large number of parts and connections. Furthermore, it is heavy, making it more difficult to transport and manoeuvre into its final position. The inner and outer walls increase structural rigidity for lifting, but also add to weight. A bespoke lifting trolley is required to lift the utility station into position. Access for fitting of the service conduits between the inner and outer walls during construction also adds to complexity.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems.

STATEMENT OF INVENTION

According to the present invention there is provided a prefabricated shell for forming a prefabricated utility room for a building, the shell comprising: a substantially U-shaped metal wall having a first side, a second side parallel to the first side, and a rear side perpendicular to the first and second sides and connecting them together to form the U-shape, the inner part of the U-shape forming the inside surface of the utility room, in use, the wall being formed from a substantially single skin, the skin being provided with a plurality of cut-outs for accessing services and/or conduits disposed to the rear of and attached directly to the outside surface of the skin.

Advantageously the single skin construction significantly reduces the complexity of the prefabricated shell. It reduces materials, weight and reduce cost. Most significantly, because the shell is formed from a single skin, conduits and service connections may be provided directly on the rear or outer side of the skin. This makes assembly of the prefabricated or packaged utility room much easier, because the parts are more accessible (ie are not fed between inner and outer walls). The inside surface of single skin forms the visible inside surface of the utility room.

The substantially U-shaped metal wall may be made in three parts, for example, the first side, second side and rear side. The parts may be connected together.

Construction of the wall in three parts enables the smaller parts to be more readily pressed, cut and folded.

Areas of the sides may overlap where they are connected together. The parts may be connected together using slot and tab connections between the parts. Alternatively, or in addition, the parts may be connected together by mechanical fasteners, for example, rivets or bolts.

A first frontal section and a second frontal section may be formed at front edges of the first and second sides respectively. The first and second frontal sections may be formed by folding.

The first and second frontal sections may lie perpendicular to the first and second sides. The first and second frontal sections may lie to either side of the U-shape. The first and second frontal sections may be folded back towards the rear side at their outer edges. The frontal sections may form the visible fronts of a door frame for hanging doors across the front of the utility room. Advantageously, the folded sheet material provides a clean edge for fitting into a recess and the folds add strength and rigidity for hanging of doors.

The frontal sections may effectively be door posts and may form the outer edges of the shell.

Clips may be attached directly to the outside surface of the skin for attaching conduits. Alternatively, other fixing means can be fitted to the outside surface of the skin. It will be appreciated that in use, the outer surface of the shell will be hidden from view inside a recess or walls or partitioning of a building.

Tabs may be folded down towards the inner part of the shell for supporting a worksurface inside the utility room.

An upper section may connect to and extend between the first and second sides. Cupboards may be formed and connected to the inner part of the shell.

At least one flange may be provided to the outside of the skin at the periphery of at least one of the cut-outs. The or each flange may provide a fixing position for conduits or other service provision. The or each flange may mount a door.

The at least one flange may be integral with the skin and may be formed by cutting and folding. The sides of the prefabricated shell may sit on and may be connected to a base unit.

The base unit and/or upper section may provide rigidity to the shell.

The base unit may incorporate adjustable feet for levelling the prefabricated shell on a substrate of a building. Lifting points may be provided at the sides of the base unit for lifting the shell inside a building, where there is minimal headroom.

Lifting points may also be provided at the upper end of the sides for lifting the shell off a lorry, for example, or when being lifted by an overhead site crane. BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which:

Figure 1 shows a perspective view of a first embodiment of prefabricated shell for forming a utility room;

Figure 2 shows a plan view from above of the shell in Figure 1 ;

Figure 2A shows an end view of the side and rear walls of the shell of Figure 1 ;

Figure 3 shows a perspective view of the shell of Figure 1 with appliances and supply conduits fitted; and

Figure 4 shows a perspective view of a second embodiment of shell, including a base unit, with appliances and supply conduits fitted.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring firstly to Figure 1, a prefabricated shell for forming a utility room in a building is indicated generally at 10. The shell 10 is substantially U-shaped and is formed as a unitary wall. The wall includes a first side wall 12, a second side wall 14 parallel to the first side wall 12 , and a rear side wall 16 perpendicular to the first and second side walls 12, 14. The walls 12, 14 16 are connected together to form the U- shape.

The inner part of the U-shape, indicated at 18, forms the inside surface of the utility room and the outside surface of U-shape, indicated at 20, forms the outside surface of the U-shape, in use. This outside surface is used to hang pipes, conduits and service ducts for supplying services to the utility room. In use, this side of the prefabricated or packaged utility room will sit inside an alcove or recess, sized for the room and will be concealed from view. A primary function of the utility room is to bring all of the utilities together in one place and to hide all of the supply ducting and cabling from sight. The inside surface is visible in use. The unitary wall is formed from a substantially single skin, the skin being provided with a plurality of cut-outs for accessing services and/or conduits disposed to the rear of and attached directly to the outside surface of the skin. Example cut-outs are shown at 22, 24, 26, 28, 30 in the second side wall 14. Flanges 32 are folded back to create fixing areas to the rear of some of the cut-outs, where required.

The unitary wall is made from metal, for example, from pressed sheet steel. The sheet steel may be coated, for example, powder coated, spray painted or dipped.

The substantially U-shaped metal wall is made in three parts, namely the first side 12, second side 14 and rear side 16. The parts 12, 14, 16 overlap in places where they are connected together. Slot and tab connections between the parts are used, augmented by riveting. It will be appreciated that other mechanical fasteners and bonding can also be utilised. The overlapped parts fit tightly together and the overlap is minimal, that is, sufficient to maintain the structural integrity of the unit.

A first frontal section 34 and a second frontal section 36 are formed at front edges of the first and second sides 12, 14 respectively. The frontal sections 34, 36 form doorposts in use and add rigidity.

The first side 12 is primarily flat, with a lower cut-out 38 and a smaller middle section cut-out 40. The first frontal section 34 is formed by a first fold 42 at the front edge. This first fold 42 forms an external corner at the front of the utility room. The material is folded outward of the utility room to lie parallel with the rear wall 16. It is then folded back on itself in a second fold 44. The material of the fist side terminates approximately 50mm after the second fold 44. The visible part of the first frontal section 34, in use, is the front face between the folds 42, 44.

Flanges are formed outwardly at the upper and lower ends of the first side 12 for attaching the base and/or an upper section, described further below.

Tabs 21 are cut out and folded downwardly inside the shell 10, in the side and rear walls, for supporting a worksurface.

Lifting eyes 23, 25 are provided on the upper edges of the first and second sides 12, 14 for lifting the shell, for example, off a lorry, using a crane. Referring also to Figures 2 and 2A, the second side 14, is made in the same way as the first side 12, save that the second frontal portion 36 extends to the other side of the shell 10 and has a wider front face. Folds 42a and 44a can be seen in Figure 2A. This is because the services provided to the right-hand side of the shell and final utility room, as viewed, require more space than those at the left side.

The rear side wall 16 is substantially flat, with inwardly facing flanges 46 formed to either side. The parts are connected together with tab and slot fastenings and rivets.

Referring now to Figure 3, the outer surface of the single skin shell 10 is shown supporting conduit 48, an electrical distribution board 50, data service connections 52. An LED light 54 is provided in a slot on either side of the shell.

Cupboards inside the shell house other items, such as an MVHR unit, and underfloor heating connections can be seen at 56. A worksurface 58 is provided across the inside of the shell, which is attached to the tabs 21. It will be appreciated that the tabs can form lifting points for lifting the shell from underneath the worksurface 58.

Referring also to Figure 4, the shell 10 may also incorporate a base unit 60. The base unit 60 has a flat upper surface 62. This surface 62 is provided by an upper planar member, for example, of sheet steel. The base incorporates a pair of feet 64, at both sides of the shell, outside the skin, behind the frontal portions 34, 36. The feet 64 are height adjustable for setting the base unit 60 level on a supporting substrate. A pair of lifting eyes 66 are attached to each end of the base unit 60. These lifting eyes enable the shell 10 to be lifted inside a building, where headroom is limited. Their position at the ends of the shell 10 also facilitates carrying through a door.

Reinforcing spars or struts 68 extend across the underside of the upper planar member 62. The spars 68 are spaced apart to enable front lifting of the shell with a forklift or pallet truck. The forks can be slid under the upper planar member 62, between the spars 68.

An upper section 45 extends between the side walls 12, 14 and provides structural rigidity to the upper end of the shell. The upper section also provides an internal ceiling to the cupboard and is also a single skin. The lighter weight of the single skin shell makes lifting easier and the positioning of the lifting eyes 66 on the base, together with the ability to use a forklift or pallet truck, make the shell with base the simplest to move and install with standard on site equipment. The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.