Field of the Invention

The present invention relates to the installation to and retrieval from remote sites, such as festival fields and construction sites, of welfare units and particularly to the provision of such units at offshore installations and remote or inaccessible locations, including conflict and disaster zones. As it is essential to load and unload welfare units from transportation vehicles, each unit must include means by which it can be lifted and ideally include securing points which are rated to bear the load of the unit.

Most all welfare units are adapted to be moved by lifting, tilting or hoisting. In many instances tine-receiving slots are provided in a base or base platform to facilitate the use of a forklift or trolley, however, there are limited circumstances in which such are available or can be used across the terrain or at the remote location. Similarly, tilting of a welfare unit to allow it to be dragged or walked across a surface has limited general application and the weight of the unit is often a significant factor specially where there are full water or foul tanks adding to the overall weight to be moved. Again, the nature of the terrain is often problematic.

Hoisting is therefore the preeminent mechanism by which welfare units are deployed and recovered, although terrain and remote location continued to be factors for the use of most all lifting and hoisting apparatus.

The act of hoisting, however, necessitates a structural integrity which often adds considerably to the weight and capital cost of welfare units. There is also a need for welfare units to be robust, durable and stable. There are many additional requirements, including ease with which they can be serviced, cleaned and/or sterilised, depending on the use to which the welfare unit is put. Where additional weight due to water or effluent is present, distortion of the structure (and therefore the integrity of the seal to a water or foul tank) must be avoided.

The loading and unloading of equipment and personnel to coastal and offshore installations including wind farms provides the most significant challenges. Accordingly, the invention relates also to the installation or deployment and recovery or servicing of welfare units and most particularly toilet facilities at such remote locations.

The term “welfare unit” as used herein is directed primarily to an enclosure housing a toilet often colloquially referred to as a portable toilet or Portaloo (Registered Trade Mark of Portakabin Limited) but the term extends also to shower cubicles, changing rooms and storage facilities, including lockers. The scope of the invention however is not intended to be so limiting and should be taken to include any enclosure adapted to be deployed to remote locations and hoisted or otherwise elevated during it positioning at or recovery from a site.

This is particularly relevant where the deployment or recover weight may be significant more than that of the unit when empty and applies equally to toilet cubicles with full effluent or foul tanks as it does to enclosures such as storage lockers or tool and equipment stowage units.

The term “cubicle” as used herein is intended to indicate a unit or construction made for single occupancy and which is adapted to be arranged with additional units into a row of identical units or into a pod where the units are arranged in a back-to-back configuration (in pairs or in rows) or where access (via a door) is offset from an adjacent or linked unit.

The term “facility” is used interchangeably hereinafter depending on the noted requirement of, for example, toilet, shower, changing or storage unit needs. Background to the Invention

It is a well-established requirement to provide toilet facilities particularly for the public at outdoor functions, such as music festivals, and for site workers on building or infrastructure construction sites. In many instances, further facilities such as showers, changing rooms and storage lockers may also be required. As the locations for which facilities are required are usually remote and are often required only for set short-term intervals (making the construction of permanent facilities economically unviable), there is an ongoing requirement for light, robust, reuseable and relatively inexpensive solutions.

Furthermore, as the toilets often require the confinement and eventual removal of additional weight, whether in the form of human waste, water which has been treated or has detergents or chemical additives therein (and cannot be disposed of at the remote location) or includes stored equipment therewithin, there is an additional requirement for the cubicles to be able to support such additional weight, particularly when being moved or hoisted.

There is extensive prior art relating to static and modular welfare units and to there being replaceable foul tanks, however, these disclosures have a dearth of detail regarding the integrity of the unit structure, particularly when hoisting.

Japanese Utility Model Patent Publication No. 1-102305 discloses a welfare unit having a base incorporating a foul tank to which four static lifting bolts are attached and to which hoisting ropes or straps are secured. The ropes are passed through great guiding holes within a roof cap. In a first illustrated construction, the lifting bolts are attached to the corners of a base place positioned over the foul tank. In a second construction, the ropes or straps are secured to hitching points along the sides of the base of the foul tank and rope channels are defined within the sides of the cubicle enclosure. In a final illustrated construction., static lifting bolts are anchored to the corners of the root cap.

Japanese Patent Application Publication No. 2005036513 to SEKISUI HOUSE KK et al. describes a toilet cubicle having a toilet enclosure securely mounted on a base incorporating a foul tank. In order to give the assembly a more aesthetic appearance, a modular frame is constructed around the enclosure to support a screen. The frame forms a periphery around the enclosure together with a toilet or foul tank on which the enclosure sits. The frame does not provide structural integrity to the cubicle and means are provided to secure the cubicle to the ground by threading straps over the roof of the cubicle and utilising stakes for fixing the straps under tension.

Japanese Patent Application Publication No. 2014079421 to MINORU KASEI KK describes a toilet cubicle having a walled enclosure together with a toilet or foul tank on which the enclosure sits. There is provided a pair of lifting members each having a central bottom plate and side plates to form a substantially U-shaped bracket to engage the bottom of the toilet tank. The side plates are fixed to the side surfaces of the toilet tank and include hooking members to engage lifting ropes or straps which pass though guide apertures along the sides of a roof cap. End loops are shown engaging a hoisting hook.

It is an essential constructional feature of all such facilities that they are sufficiently robust to be lifted into and out of position repeatedly without damage or distortion and it is this aspect that has proven to be so problematic heretofore.

While it is relatively easy (even manually) to load a small number of empty units (say between six and ten cubicles) onto a flatbed truck or trailer, it is a different proposition when attempting to manoeuvre cubicles carrying stored fluids or materials. In many instances, for convenience, toilet cubicles may be pre-filled with odour neutralising or sanitising chemicals thereby making manual loading and unloading impractical or risking spillage of stored contents.

As noted above, the site requirements may dictate the transport requirement and this is particularly true for costal and offshore locations. Traditionally for oil rig and windfarm installation of these facilities, cubicles are loaded into and secured within shipping containers which are then hoisted onto boats at quayside sites having the necessary container loading cranes. This severely limits the number of locations from which toilet and additional facilities can be serviced and also means that the remote locations require similar equipment to handle the unloading and loading of shipping containers. More often, individual cubicles are transferred from ship to shore and visa versa.

As will be well appreciated, the risk of damage to the welfare units is high and the entire process from collection to delivery is both time-consuming and fraught with challenges.

The inventor of the present invention has considerable familiarity with the loading and unloading of materials and personnel at remote offshore and costal locations and has identified and provided numerous technical solutions relating to the general art.

In UK Patent Application Publication No. 2 472 232 there is disclosed a watercraft with a retractable deployable sponson to assist in stabilising the craft during the loading and unloading of materials and personnel from the deck of the craft. The disclosure relates particularly to transport of maintenance personnel (and consequently their equipment) to offshore wind farms. It was found additionally that the deck area adjacent the sponson position facilitated the use the watercraft to load and unload, directly from a quayside to the deck, items that would otherwise have to be hoisted to and from the deck.

The above disclosure was followed shortly by UK Patent Application Publication No. 2 473 490 which builds on the utility of the earlier publication and discloses a watercraft incorporating a platform for docking with a wind turbine. More particularly, the disclosure relates to the docking directly with a transfer station attached to the mast of the wind turbine. The platform facilitates the substantially constant positioning of the craft with respect to the turbine transfer station allowing for safer transfer of maintenance personnel and equipment. A method of transferring crew from a watercraft to another structure using the platform is also disclosed.

As the size of wind farm installations grow, there has been an increasing need to provide maintenance infrastructure at remote offshore sites or at least to provide a centralised transfer location from maintenance operations may be coordinated. As maintenance crews become larger or are called to attend more frequently, the need for welfare units has grown.

Heretofore, the provision and servicing of such units has been arduous and labour intensive, requiring the attendance of vessels having the capacity to carry shipping containers as outlined in the preamble of the disclosures of United Kingdom Patent Nos. 2 567 933 and 2 579 284 (in which the present inventor is also identified).

Each of these disclosures relates to the provision of a welfare unit for the offshore sector which is individually hoistable by virtue of its placement within a lifting frame. At each of the upper comers of the lifting frame are fixed brackets within which shackle holes are provided (padeyes) so that a hoisting strap assembly is operatively attached to facilitate lifting of the framed welfare unit.

A further problem associated with existing portable toilets where, in the event they are knocked over (whether deliberately or accidentally), the contents of a foul storage or effluent tank can be discharged into the toilet cubicle itself and possibly onto the surrounding area where it may pose a contamination or health risk.

The aforementioned UK Patents disclose a suggested solution by providing a sealing means between the toilet bowl and its hinged seat and lid.

United Kingdom Patent Application Publication No. 2 601 896 (in which the present inventor is again identified) is directed particularly to the provision of a toilet facility within a wind turbine tower and presents a cubicle for installation during construction of the turbine tower or for retrofitting thereafter. To obviate the use of conventional cubicles about which hoisting frames must be fitted (such as those disclosed in United Kingdom Patent Nos. 2 567 933 and 2 579 284) there is provided a framework to which privacy panels are mounted, one of which incorporating an access door. As before, hoisting padeyes are provided at the upper corners of the framework to facilitate initial positioning of the cubicle. A replaceable cassette system is provided for the removal of waste. Each of the prior art solutions present disadvantages and technical compromises which have not been successfully addressed in a single solution. One of the most significant issues arising is the empty weight of the subject welfare unit and the lifting capacity of the hoisting mechanism. Where a boat deck mounted derrick or davit is utilised, the lift height becomes critical. In much of the prior art, lifting ropes or strap assemblies add significantly to the overall height at which a davit must operate and may prevent the unit clearing the gunwale or transom. Where a unit is to be lifted to or from a loading platform of a wind turbine, for example, lift height is also a factor which may in many instances be compounded by the presence of safety or guard rails over which the units must be hoisted. Furthermore, lifting ropes and strap assemblies must be certified and inspected regularly. Any damage will necessitate replacement. Where protective frames are added to the units, the overall increase in weight may exceed the lift capacity of smaller hoist mechanism (safe working load), particularly those mounted on vehicles (including boats) where stability may become critical. Additionally, due to the aggressive nature of seawater particularly and weathering generally, units having exposed metalwork and welds are vulnerable to a degradation.

It has been observed that some welfare units are formed so as to be recycled rather than serviced and redeployed. However, facilities for recycling rarely have the infrastructure to attend to the process. As a result, units are often disposed of improperly, dumped or put to storage and are replaced rather than recycled as intended. Due to their lack of robustness, their longevity in the field is minimised and this has a knock-on environmental effect.

As will be readily appreciate from the patent literature, there are many different approaches taken to solving some of the technical disadvantages. Each area presents specific concerns, however, many aspects are common and will be addressed hereinafter.

It is an object of the present invention to seek to alleviate the disadvantages of the prior art arrangements and to provide a load-rateable welfare unit for field and offshore locations which is robust and has enhanced durability. It is a further object of the present invention to seek to provide a welfare unit having additional features which in combination provide superior utility and functionality on location.

It is an object of the present invention to provide a welfare unit having high structural integrity at minimal empty weight, for increased safe working load, from a single lift point at a lower hoist height than heretofore.

It is a further object of the invention to obviate the use of lifting straps or strap assemblies during hoisting and manoeuvring.

Furthermore, by obviating external frame elements, exposure to degradation of fixings, welds and frame components by weathering and corrosion is substantially eliminated.

This is an object of the invention to provide a welfare unit that is corrosion resistant and has long service intervals and working longevity.

The invention is also directed to overcoming the known problem of spillage of collected waste matter, particularly where the welfare unit is or includes a toilet, when the unit is moved, knocked over or recovered from the remote location for emptying, cleaning and reinstatement or redeployment.

It is a further object of invention to increase welfare levels within said welfare units by providing improved waste retention (anti spillage means) and mitigate substantially the ingress of foul odours to the cubicle.

It is also an object of the present invention to provide an apparatus that is easily retrofittable, which is not labour-intensive and includes elements which may be replaced by unqualified individuals.

It is a further object of the present invention to provide a method of forming a welfare unit having advantageous characteristics and features. Summary of the Invention

In a first aspect of the present invention there is provided a welfare unit comprising a substantially unitary body defining an enclosure having an access door and fittings associated with the function thereof, and including a roof section upon which there is disposed attachment means by which the welfare unit is secured to a lifting hoist wherein the attachment means is retained within the enclosure and is attached to frame elements integrally formed with the unitary body to transfer lifting forces applied via the attachment means throughout the unitary body thereby to present a measurable and rateable lifting weight (safe working load) of said welfare unit substantially greater than the inherent weight of the enclosure, access door and associated fittings.

Thus, the rated lifting weight of the enclosure via the anchor/attachment point is designed to exceed the weight of the enclosure when empty therefore facilitating load capacity within the enclosure (whether for tools, fresh water, contents of foul tank, etc. etc.) when deployed to or recovered from a remote site.

Ideally, the roof section is sloped or domed to define a central apex at which the attachment means is secured. This arrangement facilitates more even transfer of the lifting forces from the attachment means throughout the body of the enclosure via the frame elements integrally formed therewith. More particularly, the positioning of a single attachment means at the apex of the roof section not only eliminates the need for a hoisting harness assembly but also lowers the overall lift height at which a crane or davit engages the attachment means.

In a preferred construction, the frame elements are integrally formed during the forming of the unitary body defining the enclosure.

Advantageously, integral ribs or larger cross-sectional frame elements are provided at or adjacent each comer of the enclosure and around an access door aperture.

Conveniently, the integral ribs or larger cross-sectional frame elements define the door aperture. Preferably, the unitary body includes encapsulated frame elements which are laid down and positioned during a moulding process selected from blow-moulding, rotational moulding and fibreglass moulding.

Most preferably, the encapsulated frame elements are embedded within the enclosure structure during said moulding process, the frame elements being selected from integrally moulded ribbing, steel strapping or carbon fibre tape entrained during moulding.

Conveniently, the welfare unit is of a monocoque construction in which the enclosure provides all the structural integrity to provide the required load rating.

The attachment point ideally comprises a captured threaded nut retained centrally within a roof section of the enclosure and supported by the frame elements thereof, thereby providing a single attachment point for engaging a correspondingly threaded bolt for hoisting. An aperture is provided to engage a correspondingly threaded eye bolt for attachment during hoisting.

Advantageously, the attachment means includes an annular flange to transfer lifting forces to the integral frame elements of the enclosure.

In a preferred embodiment, a single reinforced attachment point is integrally formed at the apex of the sloped or domed roof section of the enclosure during the forming or moulding thereof.

The present invention further provides a method of forming a welfare unit comprising an enclosure having frame elements integrally formed therein, the method including: forming by moulding an enclosure body having a back wall, a pair of perpendicular side walls and a front wall within which a door aperture is formed; forming by moulding integrally with said walls a floor section and a roof section; providing within each wall and floor and roof section reinforcing frame elements; forming a means for attachment centrally within the roof section to facilitate hoisting of the unit; fitting within the enclosure components defining the utility of the welfare unit; and mounting a door within the door aperture;

Preferably, the attachment means is secured at the apex of a sloped or domed roof. This arrangement ensures that load forces are not focused at the upper corners of a cubicle enclosure as heretofore and that the lifting forces are distributed more evenly throughout the unitary body of the welfare unit.

Conveniently, the integral frame elements transfer lifting stresses from the attachment means substantially throughout the body of the unit.

Brief Description of the Drawings

The present invention will now be described more particularly with reference to the accompanying drawings which show, by way of example only, an exemplifying embodiment of welfare unit comprising a toilet cubicle together with illustrations of supplementary components for an assembly system and method of assembly of a welfare unit in accordance with the invention. In the drawings:

Figures la and lb are schematic perspective views of prior art arrangements of welfare units comprising toilet cubicles suitable for hoisting by lifting apparatus;

Figures 2a to 2c are schematic perspective views of a prior art toilet cubicle, U- shaped hoisting bracket and a base mounted foul tank; Figure 3 is a schematic perspective elevation of a prior art construction of welfare unit comprising a toilet cubicle retained within a frame on which a camouflaging or aesthetically pleasing cover is mounted;

Figure 4 is a schematic front elevation of an exemplifying prior art welfare unit in side-by-side comparison with a welfare unit of the present invention to illustrate the height advantage achievable;

Figure 5 is a schematic front elevation of a monocoque welfare unit of the invention;

Figures 6a and 6b are schematic side and rear details respectively of the welfare unit of Figure 5;

Figures 7a to 7e are schematic sectional detailed side and plan elevations of frame elements formed within the wall structure of the welfare unit, the provision of a handle (which also may be used for coupling the units together) and one of a pair of dolly wheels;

Figures 8a to 8c are plan and side elevations of the roof region of the welfare unit detailing the integration of the frame elements with the attachment means by which the welfare unit may be hoisted; and

Figures 9a to 9f are illustrations of additional components of selected welfare units to enhance their utility and meet end user requirements, including a rotatable hoisting eye (swivel lifting eye), a dolly wheel, a slide valve, a louvered vent, a level gauge for a foul tank and a “witch’s hat” valve, respectively.

Detailed Description of the Drawings

Referring to the drawings and initially to the illustrations of prior art welfare units which exemplify some of the inherent disadvantages associated with previously prevented welfare unit solutions. In Figure la, there is shown (from Japanese Utility Model Patent Publication No. 1-102305) a welfare unit comprising a cubicle having a toilet outlet to a ground-engaging foul tank through a base plate. On the top of the cubicle is a roof cap having guiding holes at each comer to accommodate lifting ropes which are secured to static lifting eyes fixed to the base plate. In an additional embodiment (not shown), the lifting eyes are fixed to the roof cap. In each instance, hoisting is conducted via lifting ropes attached to the four eyes. In Figure lb, a welfare unit comprises a toilet cubicle which is attached by bolts to a base mount incorporating a step and foul tank. A frame is mountable around the cubicle on which a screen is hung for privacy protection, as detailed in Japanese Patent Publication No. 2005 036513.

As illustrated in Figures 2a to 2c, Japanese Patent Publication No. 2014079421 also discloses a welfare unit adapted for hoisting via lifting ropes each of which are secured through one end of a pair of U-shaped brackets which pass under a base plate within which there is a releasable foul tank. Each rope passes through a guide bracket on or adjacent a roof cap of the welfare unit cubicle and attaches to a hook of the hoisting apparatus or crane. It will be seen that the hoisting point represented by the hook is significantly above the top of the roof cap adding between one third and one half of the total height of the welfare unit to the required clearance that must be achieved by the hoisting apparatus.

Figure 3 shows a welfare unit mounted on a frame for the purposes of camouflage or aesthetic appearance. No consideration is given in United States Patent Application Publication No. 2021 0238879 to the lifting of the welfare unit in its frame. This is in marked contrast to the disclosures of United Kingdom Patent Nos. 2 567 933 and 2 579 284 in which a rateable lifting frame is provided.

As exemplifying of the prior art and described in detail in UK Patent No. 2 567 933 there is shown a toilet cubicle secured within a lifting frame having a base plate and a plurality of comer uprights welded to a top frame which is provided with shackle loops or padeyes to accommodate a lifting strap assembly which presents a centrally disposed lifting point.

Typically, the frame is made from 50mm tubular aluminium stock to save on the overall weight and to obviate the weather proofing required with other stock materials. To support the weight of the toilet cubicle, a base plate of approximately 10mm thickness is required and profiled aluminium brackets are provided to secure the cubicle thereon. To form a single hoisting point, at the top of each frame upright a triangular gusset plate having a drilled padeye (to 16mm) to accept a safety shackle (rated at 2 tonne), is welded to the upright and the corresponding upper frame elements. To connect the shackles to a central lifting eye, an assembly of (0.6 m, 2 foot) webbing straps is provided.

Of the major disadvantages associated with the prior art arrangement, the frame construction requires skilled assembly which is subjected to a lift test by an accredited body which requires recertification annually. The test is carried out to provide a safe working load (SWL) of 1000kg [1050kg]. The testing does not obligate the user to quantify the potential loads that may be added to the total weight of a toilet cubicle with a full foul tank and fresh water source. Additionally, the webbing straps must be tested regularly as they are exposed to mishandling and extreme environments.

It should be noted that with a frame height of 2.35m and purpose-made padeyes, when the four-point sling is added, it is another 0.8m (80 cm) to establish the overall hook height (that is, approximately 25% higher than the cubicle height). Furthermore, for rigidity at mid height along each upright, a bumper frame is provided around three sides allowing opening of a toilet access door. The horizontal frame (mid height) tubes stand prouder of the frame establishing a 1.25m maximum depth/width.

Web lifting straps are certified in the same manner as the lifting frame. Each welfare unit weighs approximately 160kg when prepared for deployment and they can hold a maximum of 300 litres (approximately 300 kg) of waste.

The clamps that hold the units are profiled aluminium intermediary brackets that hold the base to the welfare unit by carrying the weight of the unit of the base plate and clamping the unit to the plate using a profile bracket in each corner.

The frame is then subjected to a lift test by an accredited DNV (Det Norske Veritas). Having DNV class type approval builds confidence and demonstrates that the system has been assessed to industry leading standards. Certification is required annually and may involve non-destructive testing of each of the welds on the exposed frame.

On both sides of the frame there are two triangular gussets welded to the mid height bumper frame to allow the units to be bolted or connected together.

It will be appreciated by the skilled addressee and that there are certain inherent duplications in structure when combining a toilet cubicle or other welfare unit within a (rated) frame.

As will be seen from the height comparison illustrated in Figure 4, the welfare unit of the present invention has a single attachment point, to which there is attached a swivel hoist ring, secured at the apex of the sloped or domed roof to integrally formed frame elements continuous with the other frame elements embedded within the walls and base of the unit, thereby obviating the requirement for multiple attachment points. The lower lift height also offers additional advantages in handling, lifting and safety. This is particularly relevant for circumstances where clearance and the height to which a hoisting crane or davit may lift the unit.

The welfare unit of the invention will now be described in more particular detail with reference to Figures 5 and 6.

The welfare units may comprise a shower or changing facility, a storage locker or a toilet cubicle 1 as exemplary of the use to which such units are employed. As noted above, and particularly when located at coastal and offshore sites, units are exposed to harsh and corrosive conditions and, despite their clear necessity, are often treated with contempt. The welfare unit of the present invention is designed as a unitary body 2 with a monocoque style structure having no exposed welds, joints or metal parts, save for the single attachment point 4 within which a swivel hoist lifting ring 5 is secured. The lifting ring may be galvanised or painted to protected it from corrosion or may be made from a material, such as stainless steel, known to have a long service life in such environments.

The unitary body 2 is formed using one of a number of preferred moulding techniques (as discussed in more detail below) to present a tough, resilient exterior with enhanced UV protection. An access door 7 is located in an (ideally framed) aperture and has a peripheral sealing lip 8 to overlie the door aperture which may include a strip of neoprene foam tape or a recess-engaging profile for enhanced weather resilience. The aperture ideally includes a strengthening frame comprising interval frame elements for additional structural rigidity. Along one edge of the door, hinge mouldings 9 are provided, each having locator pins 11 adapted to engage corresponding receivers positioned within the unitary body adjacent the door aperture. Along the opposite edge, a latch mechanism 13 is provided within a moulded recess 14 and is adapted to engage a receiver 15 along the internal edge of the door aperture. The lower edge of the door aperture includes a tall, stepover threshold (similar to a bulkhead aperture) to serve both as a means to prevent ingress of rainwater and, should there be an inadvertent spillage from the toilet or foul tank during transport, contaminated water is constrained within the cubicle. In the preferred construction detailed below, anti-spillage and odour control is discussed further. In an alternative construction, the door aperture and corresponding door is substantially ovoid. This modification eliminates stress risers at the door aperture and allows applied lifting forces to be directed elsewhere through the unitary body.

To the rear of the unitary body 2, a manoeuvring hand aperture 17 is disposed at or towards each side edge but it is conveniently positioned to coincide with a frame element whereby a handle 18 is formed around said frame element (as detailed in Figure 7d). A dolly wheel 21 is mounted on a stainless-steel axle 22 constrained within a wheel mounting aperture in the rear of the cubicle at or adjacent the base thereof, the axle being optionally reinforced as illustrated in Figure 7e.

Although reference is made herein interchangeably between monocoque cubical and unitary body, in strict terms a monocoque frame takes its structural integrity from the external skin or moulding and additional elements are then added. The utility of an external frame has been noted in the prior art and the transference of an external frame to one within the cubicle itself may address certain disadvantages but would encroach on the space to be utilised (often with standard internal fittings such as toilet assemblies, wash basins or hand sanitisers). The present invention, however, presents a welfare unit in which frame elements 25 are integrated into the moulding to enhance the stability and rigidity of the monocoque cubicle and provide a unitary body which addresses numerous perceived disadvantages.

The monocoque structure provides a means to eliminate the lifting frame entirely by making the welfare unit as a whole liftable and certifiable as such. The utilisation of a single attachment point 4, into which standard rated central lifting eye 5 (ideally in stainless steel for the harsh offshore environment) is locked, means that only a visual inspection may be needed to pass annual certification requirements. As the lifting eye 5 will often be significantly over-rated (for example, by utilising a widely available 2-tonne rated swivel lifting eye), it will not represent a potential failure point unless exhibiting significant physical damage. Similarly, due to the moulding techniques employed to construct the unitary body, any stress risers will be visually apparent. As there are no welds employed, the need for crack testing is redundant.

Advantageously, the attachment means may comprise a threaded lifting eye bolt receiver either directly within a frame member or overlapping frame members to provide the required integrity to transfer the lifting forces throughout the unitary body. In a preferred construction, a retained receiver nut is bonded into the apex of a domed roof 30 and supported therein by the internal frame elements. In the particular instance where steel mesh webbing or carbon fibre tape is embedded in the moulded composite, the frame elements may be integrated with the attachment means or retrained thereto using load stress relievers such as flange elements 42 at the centre of the domed roof. Further strength and rigidity may be added to the domed rood by the inclusion during the moulding process of spoke-like ribbing.

Additionally, the profile of the domed roof 30 allows maximum internal height to be maintained without adding to the total hoisting height and this in turn facilitates the use of the welfare unit of the invention in locations where the hoist height precludes use of the majority of prior art units. The roof dome profile is determined by the moulding technique used so as to efficiently and effectively transfer load stresses evenly throughout the unit, thereby eliminating stress risers within the unitary body. Furthermore, the dome of the roof is designed to be kept as low as possible in order for the welfare unit to be lifted beneath, for example, a turbine davit crane onto a transition platform_without reducing interior space and with its lower overall height allowing a banksman to manoeuvre easily a hoist hook onto the lifting eye. Where a welfare unit is to be lifted to or from a loading platform of a wind turbine, the lower lift height allows for additional clearance of guard rails. Overall, the elimination of hoisting strap assemblies and the provision of a single accessible attachment point significantly improves the handling and manoeuvrability of welfare units for general or specialised remote location transport.

As stated above, there are several moulding techniques which can be applied to the formation of the unitary body forming the welfare unit of the invention. With reference again to Figures 5 and 6 and with particular additional reference to Figures 7a to 7e, the techniques available will be discussed.

The monocoque style unitary body may be fabricated from glass fibre composite laid over Corecell - a medium to high density foam core used in boat building (Corecell is a registered trade mark of Gurit (UK) Limited) - using either epoxy resin for high resilience and durability in very harsh environments or a polyester resin to keep costs lower. A UV stabiliser may be added where required. It will be appreciated by the skilled addressee that references to fibreglass and associated moulding techniques include all those materials and techniques generally covered by the respective terms and include fibre reinforced polymers and composite plastics materials of all suitable varieties, including carbon fibre composites and synthetic fibre composites, including polyaramid fibre composites such as Kevlar (Registered Trade Mark)

In a first construction, an outer or exterior facing layer 32 of glass fibre is laid into a preformed mould, access being provided through the door aperture (and base if constructed at a later layering up stage). Frame elements 25 are positioned within the mould and subsequent laminated layers 34 are overlaid onto the existing exterior facing layers 32 and frame elements to entrain them effectively within the glass fibre and resin composite. Further finishing layers 36 are then applied with preforms being used for fitment details. Standard finishing and dressing of the final surfaces 36 is conducted before fittings and fixtures are secured to the body.

It will be appreciated by the skilled addressee that the frame elements 25 may comprise different materials or be formed using existing fibre-glassing techniques. In one variation, metal frame elements are assembled within the mould before the subsequent laminated layers 34, 36 are applied. The fibreglass and epoxy mix ensures air or water cannot penetrate to the frame elements when the welfare unit is deployed, decreasing significantly the degradation of metal frame elements by corrosion. In another variation, strengthening ribs are formed during the fibreglass moulding operation, building stability and rigidity into the body 2 as it is formed.

In a preferred variation, steel webbing or carbon fibre cloth tape is entrained as the frame elements within the glass fibre mould. In Figure 7a, a sectional side elevation of a wall segment illustrates the building of layers from an externally facing foundation layer 32 on which additional layers are formed before a centrally disposed frame element 25 is laid down. Further layers 34 entrain the steel or carbon fibre webbing before a final internal facing layer 36 is applied. Figure 7b shows a sectional plan elevation corresponding to the layup described with respect to Figure 7a.

Additionally or alternatively, frame elements are integrally formed in the unitary body by forming solid material corner cross-sections within which stainless steel webbing or carbon fibre tape is optionally entrained.

In a proposed construction, four 50mm (2 inch) wide carbon fibre cloth tapes in multiple laminated layers are provided in unbroken path from the centre of the base to the corners thereof, along each corner upright and from the comers of the domed roof section to the central (ideally stainless steel) lifting eye at the apex of the roof. Thus, each tape is capable of transferring the lifting forces concentrated at the lifting eye evenly throughout enclosure frame.

The four tapes creating the load path will preferably be made from three individual overlapping left and right 50mm (2 inch) wide tapes creating enough strength to pass any certification test and take a high fall without damaging the unit beyond serviceable use. The carbon tapes in the domed roof running from each comer to the apex of the dome can be arranged like the spokes of an umbrella between the built-up layers of glass fibre to a securing flange 42 at the roof apex where a retaining nut 4 is embedded within the fibreglass to receive the fixing bolt of the central lifting eye 5.

The composite glass fibre structure should preferably be vacuum infused. Alternatively, a wet layup technique can be followed by vacuum bagging to draw out excess resin thus reducing significantly the weight over a straight wet layup method. Oven cure would be advantageous to achieve resin strength optimization.

In an alternative construction, standard blow moulding techniques may be adapted to fit to or entrain the frame elements and give enhanced structural integrity and strength to a manufacturing method normally associated with low cost and often disposable welfare units.

In a preferred construction, a rotational moulding technique is used in which frame elements are placed within a mould prior to rotation and injection of the chosen thermoplastics material. As noted above, the frame elements may comprise corner cross-sections of the moulding material to provide the structural integrity of the unitary body. Additional ribbing may be provided along the walls, base and domed roof section.

As shown in the sectional plan view of Figure 7c, the frame element material 25 is entrained within the moulded plastic material 40 and is substantially immune to corrosion. In Figure 7d, a side sectional elevation of a handle aperture 17 shows the entrainment of the frame element 25 within the handle 18 adding strength and rigidity thereto. Similarly in Figure 7e, an exposed side elevation of a rear corner of the welfare unit shows a dolly wheel 21 mounted for rotation on an axle 22 which penetrates a moulded aperture. The aperture and axle 22 are strengthened by the frame element 25 embedded within the moulded wall material 40.

Rotational moulding may increase the weight but given the robustness and potential cost savings over the glass fibre layup technique (which is normally labour intensive) it is a preferred option. Given that the welfare unit may be provided with integral dolly wheels and may include manoeuvring handles, the weight is easier to handle. Traditional units are simply dragged across ground or “walked” over floor surfaces.

As before, the frame elements may be incorporated in a number of ways. There is the option for having a carbon tape or stainless-steel skeleton inside the mould with stainless steel mesh flooring provided as an integral base. Stainless wire verticals/uprights in each of the corners combined with stainless steel mesh over carbon fibre or steel tapes in the domed roof 30 will spread the lifting load through the rotational moulded plastic roof section to the lifting eye 5.

Figures 8 a to 8c detail optional configurations of the frame elements 25 where they interact with the attachment point 4 at the apex of the domed roof 30. Ideally, the attachment point 4 comprises an imbedded retaining nut adapted to receive the corresponding threaded bolt of a swivel lifting eye 5. The retaining nut is embedded within the moulding material 40 and flanges 42 are optionally provided to attenuate stresses at the nut. Most ideally, the frame elements are in the form of steel or carbon fibre webbing acting together with the flanges to spread the lifting forces throughout the unitary body 2. In a first arrangement, webbing in uninterrupted length from the base of the body rises adjacent the corners of each side wall of the cubicle and join together at the apex of the roof, where it encircles the attachment point 4 and provides further attenuation of lifting stresses through transfer via the or each flange 42. In a second arrangement, the load carrying webbing splits to accommodate the attachment point 4 and is arranged as an unbroken loop around the entire cubicle.

The base floor may comprise either Corecell (RTM) if a composite is used or an aluminium honeycomb or stainless-steel mesh if a rotational moulding technique is used.

Polyethylene terephthalate (also referred to simply as polyethylene [PET, PETE]) is used in the vast majority of rotational moulding applications. Polyethylene is also highly recyclable.

The single point lifting eye 5 of the type shown in Figure 9a negates the requirement of four lifting straps and shackles, which all require individual testing and certifying. The central lifting eye can be directly attached to the hoisting hook of a crane thus significantly reducing the lifting height under a turbine davit.

Plastic dolly wheels as illustrated in Figure 9b can be mounted in such a manner that they only contact the ground when a handler tips the welfare unit rearwardly so that it can be rolled into position like a sack barrow. Handles 18 are provided on the rear of the cubicle approximately midway up the walls at the rear corners or closely adjacent thereto so that the carbon fibre tape or stainless- steel wire mesh webbing is coincident with and running inside the handles. The handles can also be used as a convenient point for deck lashing during storms. As the units are relatively lightweight, they are sensitive to winds over Beaufort 4 and a lashing eye (not shown) may be provided on each side also. These can be integrally formed during moulding. Obviously, the swivel hoisting eye 5 at the roof apex may also be used with a through rope for lashing to a deck or other secure point.

It will also be apparent to the skilled reader that the handle can be used to secure adjacent welfare units to another. This can be in a simple side-by-side or back-to- back configuration. Additionally, a row of back-to-back units may be secured together to form a block. The units may be secured together by standard zip ties (cable ties) or a spinnaker release type mechanism. Optionally an over-lever latch may be used.

A particular problem appreciated with welfare units incorporating or comprising toilet cubicles is the potential risk of spillage from the foul tank. Where toilets are not secured, they can be blown over in high winds and, notoriously at music festivals, they can be deliberately tipped over (occasionally with an occupant inside). While the solution offered in UK Patent Publication No. 2579284 provides enhanced protection to foul spills and potential contamination of the surrounding environment, that protection is wholly dependent on the user closing and sealing the lid with a clamping strap to engage the seals provided between the toilet bowl rim, seat and lid. Furthermore, this offers no protection to an occupant using the toilet should the cubicle be deliberately upended.

It is an optional feature of the present invention to provide a closure valve within the toilet throat below the pan. This prevents any inadvertent spillage from the foul tank through the toilet bowl and does not rely on the action of a present or previous occupant.

Many toilets feature a flush mechanism activated by a button or lever behind an upright toilet lid so that it is essential to close the lid after use to access the flush. By using a slide closure valve 50 of the type shown in Figure 9c actuated by a linkage to the flush mechanism, the valve remains closed at all times except during the flush. Consequently, the interior of cubicle is isolated from smells emanating from the foul tank at all times and ensures spill avoidance if the cubicle is subjected to a “knockdown”.

It is also well known to provide a vent stack from the foul tank of a toilet cubicle which allows accumulated odours and expanding gases to escape to atmosphere. This, however, provides another potential leakage route should the cubical be upended. Vent stack screen caps provide protection from ingress of rainwater and act to draw odours from the foul tank but provide no additional protection against spillage. In one construction, a threaded vent pipe screen cap having a venting position and a transit position where it is screwed down to seal the vent pipe during transit is provided. In an alternative construction, a vent pipe slide valve is provided between the foul tank and the vent pipe outlet for closing during transit, particularly recovery. A mesh screen and replaceable charcoal filter may also be provided in the vent stack.

The vent stack is often provided to the rear of a toilet cubicle, however, this can impede the linking of units into a block and also presents a vulnerable feature subject to damage during transport. It is one option to provide a moulded channel in the rear or side of the cubicle to accommodate and protect the vent stack. An alternative is to provide the vent stack within the cubicle, however, extra provisions are required to ensure integrity of the domed roof and the frame elements are not affected.

Additionally and with reference to Figure 9d, a louvred air vent is optionally provided in one of the rear or side walls. This option adds to the complexity of the moulding process and it is therefore advantageous to provide the air vent in the door 7 as it is formed separately from the unitary cubicle 2. A replaceable charcoal filter is provided within the louvred vent housing.

With the provision of electrical power, additional features may be incorporated. Using solar panels mounted to the domed roof, a stored battery pack can be trickled- charged to support higher power demands or the panels alone may be used with a smaller accumulator for internal illumination via LED lighting and occupancy indicator LEDs on the door. In one arrangement, the solar panels are accommodated in a protective recess formed in the domed roof during the moulding process. In an enhanced arrangement, solar panels are mounted on a tiltable platform for optimal positioning or automated sun-tracking. By utilising deep cycle batteries which can be easily swapped out, similar to battery packs used for cordless drills, pumps and fans can improve the ‘welfare experience’ available to the unit user. Marine 24V batteries and 12V deep cycle batteries all provide interchangeable options, particularly with adaptable voltage regulation circuitry. Charging may be provided by on-site power or solar panels to increase service interval. An external mains power hook-up is likely to be available in certain locations including campsites, construction sites, municipal parks and airport long- stay car parks. At more remote locations, such as wind turbine platforms and maintenance platforms, external power may also be available. In such circumstances, multiple welfare units (optionally coupled together) may use a single power reserve linked to external power. This then presents an option for batteries to be stored in a separated pump house having a service operator key access. This is optionally associated with large volume foul tank allowing for the timed emptying of smaller foul tanks located in each toilet cubicle or for the handling of lager volumes of waste water from shower cubicles.

An electric gulper pump, designed to manage unmacerated toilet waste and can be run dry without damage, is eminently suitable for moving volumes of waste from cubicle foul tanks to a larger volume specialised receptacle. However, smaller gulper pumps can be used to aid the flush in a toilet cubicle and its operation can be associated with a toilet lid actuated pre wetting of the toilet bowl ready for use. A nano coating applied to the toilet bowl will negate effluent adhering during the flush and its operation is enhanced by pre-wetting. The coating may be provided as a plastics material wrap to line the bowl, replaceable at long service intervals.

Each welfare unit may incorporate a variety of remote querying means to provide additional operator advantages. Stock control may be provided by RFID or QR code tags for tracking technologies or associated with 2G (or higher) SIM technologies. Further remote monitoring may be enabled with line-of- sight technology for transmitting status data to an operator base or relay station and to shore from offshore windfarm locations, for example. Advantageously, a welfare unit communication module may be linked to communication apparatus fitted to offshore turbines so as to piggyback on longer range communications installations.

A fluid float switch as shown in Figure 9c may be used to indicate foul tank level visually. Where power is available, an FED can indicate that the cubicle is “Out of Order” and thereby suggesting to use another facility. Similar level indication can be provided for fresh water supply, if available. In embodiments with a communication module, a signal can be generated to indicate tank levels or cubicle swapout status. Where a foul tank level suddenly measures “Empty”, this may indicate a ‘knockdown” and trigger an alarm or set a quick response status to an operator.

Referring now to Figure 9f, a “Witch’s Hat” diaphragm valve may be incorporated into the foul tank vent tube to release expanding gases only when sufficient pressure has accumulated. This reduces emissions from the foul tank to only short, limited periods rather than being a constant lingering odour from the vent tube.

Particular emphasis has been placed on addressing specific aspects of welfare units comprising a toilet cubicle, as they embody many of the known problems inherent in remote location and offshore deployment of welfare units generally. There are particular concerns regarding boats and deck lifting equipment such as gantry cranes, general cargo cranes, derricks and davits, etc for moving loads to and from the deck of a boat or ship. Due to the extreme environment, components may wear down at an increased rate, requiring regular repair and maintenance. The present invention attempts to address the majority of these issues.

Loads should be kept below the safe working load (SWL) of the crane or hoist and ideally significantly overrated with respect to the maximum rated lift weight of the welfare unit. Hoist height, where the lifting apparatus hooks to the lifting eye, is kept to a minimum.

Each welfare unit should be a certificated for its maximum load weight so that crane or hoist operators can easily evaluate potential tilting and ensure proper distribution of the load when multiple welfare units or additional/other cargo is on board.

The whole philosophy of the welfare unit of the invention is one that is lightweight for easier handling offshore and giving an increase in strength and substantial weight reduction over the toilet-in-frame model by using modern boat building technology.

It will be further appreciated by the skilled reader that the present invention and the moulding techniques employed make the welfare units particularly suitable for inturbine installation, that is where, for example, a toilet cubicle is included in the turbine build or retrofitted. Such installations may require a removable foul tank or effluent holder (such as a ‘flexitank’) which may be fabricated from a suitable material, including Hypalon (a trade mark of DuPont Performance Elastomers LLC), for change out and service onshore. Flexitanks can be hung or sat on strain gauges to monitor effluent capacity on site and remotely. A flexible 25mm (1 inch) vent tube on a flexitank connecting onto a toilet cubicle toilet “hard” vent tube with a quick-connect coupling for fast removal and capping from the flexitank vent tube prepares it for transit.

Welfare units (and particularly toilet cubicles) of the invention have wide utility beyond offshore and remote location installation. There is wide military application for rapid deployment of welfare and storage facilities. Further application can be found in refugee centres and disaster relief where the provision of discrete toilet facilities may prevent spread of water-borne diseases and those associated with poor sanitation, such as dysentery, typhoid and cholera. With the appropriate delivery vessel, the welfare units of the invention may also be deployed at river banks and costal quaysides for further transportation inland. Single or multiple units (secured together as considered hereinabove) may be hoisted into emergency relief zones by helicopter or into such regions where there is no road access, for example, mountainous or extensive highly forested areas.

Welfare units comprising shower cubicles also present specific requirements that can be met only at locations where, unless sufficient provisions are made for stored water, a source of freshwater is needed, ideally under mains water pressure or gravity feed. Where inadequate water pressure is available, sufficient power for pumping must be provided. Additional power may be may also be required for heating water. Standard heating and pumping requirements often exceed 1200W continuous.

Many welfare units, particularly those available only to select users or for lockers and storage of tools, materials and equipment on-site, require limited access. Key and coin-operated doors are one option for lockers, showers and toilets for general use. Coded access may also be provided on door release latches. For certain applications where personal safety or incidences of vandalism and theft are prevalent, 4G, web-enabled or networked IP cameras may be installed. Welfare units of the invention may also be adapted for use as remote delivery lockers for postal drop off, campsite storage, caravan park external storage bins, tool sheds and garden storage bins.

Where there are advantages in distinguishing one type of welfare unit from another or segregating applications, colour-coding of welfare units may be employed. Although a direct solution is the application of surface paint, dyes can easily be added to fibre glass resin and to thermoplastics material prior to moulding the unitary body of the welfare unit. For military applications, camouflaging of welfare and storage units is of particular relevance. At the opposite end of the utility spectrum, the use of fluorescent or UV-reactive dyes may be found useful in such places where there is limited light or where light intrusion must be kept to a minimum. At camp sites or festivals, it may be useful to colour-code male and female toilets or shower facilities. Colour-coding of storage facilities may also be useful to categorise materials or separate, for example, potentially hazardous materials from those that are non-reactive or benign.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the appended claims.