Note: Descriptions are shown in the official language in which they were submitted.
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"PREFABRICATED BUILDING SYSTEMS"
This invention relates to building structures and the construction and
erection of
prefabricated buildings. In particular this invention relates to prefabricated
buildings
s utilising prefabricated steel framing such as relocatable buildings.
In our earlier International Patent Application No. PCT/AU 94/00335 there is
disclosed a prefabricated building system in which a plurality of similar wall
panel frame
sections are arranged with the frame side members of adjacent wall panel frame
sections adjacent but spaced apart by joining members located therebetween and
rigidly
io fastening the frame side members to one another. The spaced interconnected
side
frame members define vertical load paths centered on the space between the
frame
side members. The top and bottom joining member extend vertically beyond the
frame
side members for interconnection to complementary frame members thereabove or
therebelow. Suitably the load paths align with grid lines of a fixed floor
plan grid
is whereby wall panel sections are medially intersected by respective vertical
grid planes.
This arrangement enables standardisation and economical fabrication of close
tolerance
steel framed panels sections.
Our present system provides significant advantages over existing systems
especially in freedom of layout/roof design without sacrificing the advantages
provided
2o thereby. However it does not specifically address the provision of
relocatable or remote
area accommodation such as is required for mines or to facilitate cost
effective provision
of comfortable housing in underdeveloped areas.
Preferably such relocatable accommodation is able to be containerised for
transport to or from erection sites where erection and local transport may be
2s accomplished using unskilled labour and with minimum requirement for
mechanised
assistance such as cranes and concrete batching plants. It is also preferred
that the
building panels be pre-sheeted and have window and door frames installed and
services
where possible.
Furthermore in many such applications it is necessary to form accommodation
3o structures which provide individual accommodation units for several persons
or groups
which are noise insulated from one another by respective walls with air gaps
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therebetween.
This invention in one aspect resides broadly in a relocatable building
structure
formed from transportable prefabricated panels including:-
wall, floor and/or roof panels each formed from one or a plurality of panel
sections;
s the respective panel sections include frame side members which are joined
together
during erection , either directly or indirectly, through joining members
positioned
between said frame side members to form the wall panels, the floor panels
and/or the
roof panels;
the joining members joined to the ends of the wall frame side members extend
to beyond the joined wall panel sections and provide the interconnection to
the floor and
roof panels, being joined to the frame side members thereof, and
selected wall panel sections being hingedly connected to selected floor panel
sections such that they may be raised pivotally one after the other from a
stacked
overlying position to their operative standing positions.
is The joining members may provide opposed threaded apertures into which the
wall frame side members may be bolted for direct connection to one another.
Alternatively there may be provided as a separate joining member associated
with each
wall frame side member which extends beyond the beyond the joined wall panel
sections and provide the interconnection to the floor and/or roof panels, the
separate
2o joining members joining the wall frame side members together indirectly by
joining the
respective wail frame side members to joined frame side members of the floor
and/or
roof panels. In the context where it admits such a structure, a reference to a
roof panel
may be taken as a reference to a ceiling panel.
The separate joining panels which join the wall frame side members to the
floor
2s panels may form the hinge parts mounted on the wall panel sections of the
hinge
connection between the wall panel sections and the floor panel sections.
Preferably the hinge mechanisms or mountings therefore reside alongside the
frame side members and/or in the space between the adjacent frame side members
of
mating panel sections whereby the hinge mechanism or mountings therefore in
the
so erected structure may reside concealed between the opposed faces of the
erected
panels. Alternatively temporary hinges which are removable after erection may
be used
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to elevate the wall panel sections to their operative positions.
The wall panel sections which are hingedly connected to the floor panel
sections
may also incorporate service connections such as ducting for cables or pipes
for fluids.
These may be flexible hose type connections but preferably they are in the
form of rigid
s upper and lower complementary tubes including an arcuate tube centered on
the hinge
axis, the complementary tubes being fixed to respective ones of the wall and
floor panel
sections for pivotal movement with the wall panel sections to a mating
attitude. This
may be an operative substantially abutting alignment for threaded connection
of one
with the other or both upper and lower tubes may be arcuate and arranged to
fit one
io within the other so as to maintain a constant encasement for services such
as pre-wired
electrical or data cabling. Preferably such arcuate tubes are set in from the
outer wall
cladding.
The floor panels may be of any desired configuration such as square hexagonal
or triangular in plan form but it is preferred that each floor panel is
rectangular and
is selected floor panels have respective wall panels hinged thereto by
elevated pin type
hinges providing hinge points spaced above the floor panels, and the elevated
hinges
enable pivotal movement to a standing position of successive uppermost ones of
the
wall panels which overlie the non-erected wall panels. Suitably in the
standing position
the wall panels extend across the ends of floor panels and are joined thereto
by joining
2o members disposed between spaced side frame members of respective panel
sections.
The wall panels may be clad both sides with a suitable sheet material or the
like.
The cladding may have inner and outer skins provided with offset lateral
extensions along the vertical edges and extending beyond the frame side
members
such that adjacent wall panel sections may be hinged upwardly to their
standing position
2s permitting the junction between the outer skins at each joint to be
juxtaposed the frame
side member of one of the adjacent wall panel sections and the junction
between the
inner skins at each corresponding joint to be juxtaposed the frame side member
of the
other of the adjacent wall panel sections.
Suitably the offset is such that the offset edges extend partway across the
frame
so side member of the adjacent wall panel whereby the offset edges may be
supported by
and secured directly to the adjacent frame side members when erected. The
outer
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cladding may also extend down beyond the wall frame so as to provide an
overlap
across the floor edge or foundation when the wall panels are erected.
The or each wall panel may include a support panel section hingedly connected
to a floor panel section and a fill-in panel to extend between the support
panel sections.
s The or each fill-in panel sections may be erected independently on site but
preferably
each is pivotally connected to a frame side member of a support panel section
and is
raised therewith and then may be pivoted about the frame side member to its
operative
position.
Suitably the wall panel sections hinge above further joining members disposed
io alongside the frame side members and/or in the space between the adjacent
frame side
members of mating panel sections and at the upper edge thereof providing
direct load
transfer paths to footings associated with further joining members.
Suitably the frame side members are formed as major load bearing members
which extend between the upper and lower extremities of the panel sections
providing
is load paths or composite columns at the junction of wall panel sections
permitting roof,
wall and floor loads to be transferred through the composite columns to the
footings or
floor, such as a concrete foundations or screw-in piles or the like.
Alternatively, if
desired the wall, floor and/or roof panel sections may be adapted to transfer
imposed
loads as a distributed load through horizontal edges thereof.
2o The roof panel sections may also be hingedly attached to the upper ends of
the
wall panel sections whereby their upper ends may be elevated with or after
raising the
wall panel sections, enabling erection by hinging the roof panels upwardly
from their
inverted position to an operative inclined position.
Alternatively the roof panels may be transported separately to the erection
site as
2s a separate prefabricated structure. This structure may include ceiling
panels having roof
and suitably any verandah roof panels pivotally connected thereto for raising
to their
operative positions. In one form the roof panel sections are formed in
opposing pairs
each pivotally connected to the upper end of spaced parallel side wall panel
sections
whereby they may be raised to connect their upper ends to one another to form
a ridge
3o type roof. If desired the side frame members of the roof panel sections may
be arranged
to lie in respective common vertical planes and form the upper chords of a
truss
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assembled after erection of the roof panel sections. Preferably these common
vertical
planes tie intermediate the frame side members of the panel sections of the
wall panels
and if desired the floor panels and suitably they coincide with fixed equally
spaced
horizontal grid lines.
s In another aspect this invention resides broadly in a method of erecting a
transportable prefabricated floor panel section, the method comprising:-
providing the floor panel section with supporting posts which are length
adjustable
downwardly from the floor;
lifting the floor panel section from a sling whereby the floor hangs
horizontally;
io positioning the floor panel section at the required level;
adjusting the posts to engage prepared support surtaces, and
locking the posts in that adjusted position before removing the sling so that
the
floor panel section is supported horizontally by the posts.
is Preferably the floor is lifted by a crane, and suitably by a central point
sling and
craned to its operative position. The posts may be provided with feet for
capture by
prepared support surfaces. The posts may be fixed length posts which slide
through
clamps on the floor but preferably the posts are length adjustable posts
provided with
self leveling feet.
2o Suitably the posts include a foot, an adjustable leg assembly having a
lower end
portion adapted for cooperation with a foot assembly in such manner that the
leg
assembly receives substantially axial support from the foot assembly
irrespective of the
relative angles between the leg assembly and the foot assembly within the
range of
adjustment provided. Preferably the foot assembly is plate like and is
provided with a
2s regular shaped dome supporting portion having a base width which is
significantly
greater than the tubular lower end portion which it is adapted to support and
suitably
either the tubular lower end portion or the dome portion has a cylindrical
section
whereas the other may have a polygonal section enabling the foot assembly to
provide
full support for the lower end portion at any position on the dome shaped
portion. It is
so also preferred that the lower end portion be telescopically engaged with an
upper end
portion and that locking means be provided for selectively locking the lower
end portion
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to the upper end portion at the selected length adjustment. For this purpose,
one may
be adapted to be through bolted to the other through an axial slot permitting
length
adjustment prior to clamping by bolting or each may be adapted to be through
bolted to
the other through one pair of mating holes which may constitute one of many
mating
s holes providing length adjustment of the leg assembly. It is also preferred
that the lower
end portion be interconnected with the foot assembly in a manner which permits
free
movement between the leg assembly and the foot assembly over the selected
range of
adjustments and which does not inhibit engagement of the lower end portion
with the
dome portion of the foot assembly. For this purpose it is preferred that in
one
to embodiment the dome assembly is provided with a loop which may engage
captively
about a pin extending through the lower end portion of the leg assembly.
The frame side members are suitably side members of clad panel section frames
which may be ladder type frames formed from box, tubular or open section
members.
The joining members may be formed from plate steel with threaded bolt holes
is therethrough or they may be formed as rectangular hollow section members
having
threaded bolt apertured formed in the opposite faces. Suitably the threaded
apertures
are formed as flow drilled apertures thereby forming internal threaded collars
extending
the thread length.
n order that this invention may be more readily understood and put into
practical
2o effect, reference will now be made to the accompanying drawings which
illustrate a
preferred embodiment of the present invention and wherein:
FIG. 1 is a perspective view of erected framework of a relocatable structure
having an elevated floor, walls, ceilings and a roof structure, the panel
sections being
shown unclad;
2s FIGS. 2a to 2i illustrate the sequence of erection of the framework
associated
with one floor panel section of the floor illustrated in FIG. 1, which is
formed from four
such floor panel sections and verandah sections;
FIGS. 2j to 2m illustrate the sequence of erection of the verandah, ceiling
and
roof framework associated with the structure illustrated in Figs. 2a to 21;
so FIGS. 3a and 3b illustrate typical hinging arrangements for a wall panel
section;
FIGS. 4a to 4c illustrate details of an alternate hinge mechanism for hinging
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adjacent wall panel sections to an upstanding attitude;
FIGS. 5a, 5b and 5c illustrate the various arrangements of the supporting
posts
for the framework of F1G. 1;
FIGS. 6a to 6g illustrate a floor panel section frame and its construction
details for
s both fillet welded and spot welded versions;
FIGS. 7a to 7c illustrate hinge details in plan view for infill panel sections
which
swing from the end panel sections to form a corner;
FIGS. 8a to 8i illustrate the sequence of erecting the roof structure;
FIGS. 9a and 9b provide enlarged views of the roof ridge connecting means and
io the sequence of the roof erection;
FIGS. 10a to 10d illustrate the pivot arrangement for connecting the verandah
roof to the main roof;
FIGS. 11 a to 11 c illustrate the erection sequence of an alternate form of
wall
hinge and Figs. 12d to 12 are corresponding views from the opposite side of
the hinge;
is FIGS. 12a to 12c illustrate an offset wall cladding arrangement for use
with the
hinges of Fig. 12;
FIGS. 13a to 13c illustrate details of the services connections between walls
and
floor;
FIG. 14 provides a construction sequence of a typical building according to an
2o alternate form of this invention, and
FIGS. 15 is an exploded view of a support post.
The structure 10 illustrated in Fig. 1 is formed from four prefabricated
floor/wall
modules 11 F as illustrated in Fig. 2a and corresponding roof /ceiling modules
11 R as
shown in Fig. 2k, both of which are formed to facilitate containerised
transportation with
2s other modules.
The floor module 11 F includes panel sections 12 which overlay one another in
their transport configuration with wall panel sections 14 above and connected
pivotally to
a floor panel section 15 or to one another.
All panel sections of the framework illustrated in Fig. 1 are factory formed
with
so welded unitary ladder frames having frame side members 19 interconnected by
rung
members 20.
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In the structure 10 the frame side members 19 of the adjacent floor, wall and
roof
panel sections are spaced apart by interposed joining members 21 each provided
with
threaded apertures 22 which receive opposing bolts 23 extending through
complementary apertures 66 in the adjacent webs 24 of the floor frame side
members
s 19. These joints are illustrated in Fig. 5.
The end wall panel sections 14 are connected to the floor side frame members
19
by pin type hinge assemblies 18. Each hinge assemblies 18 has a leg member 25
formed integrally with the adjacent side face of a joining member 21 and
extending to a
single pin connection 26 extending through the web 24 of the floor side frame
members
19.
The joining member 21 is bolted to the side face of the end wall frame side
members 19 and protrudes therefrom so as to effect a bolted connection to the
floor side
frame members 19 when elevated to a standing position. The pin connection is
positioned medially of the web 24 and inward from the ends of the side frame
members
is 19 as the length of the leg members 25 is such as to hold the end wall
panel sections 14
elevated above the stack of remaining wall panel sections. Thus, in the
illustration, the
right hand leg members 25 are the longest enabling the right hand end panel
section 14
to overlie all other panel sections.
As shown in Fig. 2b, the right hand end wall panel section 14 is the first
elevated
2o and it pivots directly to its operative position such that the lower pairs
of threaded
apertures 22 in the lower joining members 21 bolted thereto may be through
bolted
through the corresponding apertures 66 in the webs 24. The upstanding end wall
panel
section 14 may then be bolted in position.
The left hand end wall panel section 14 is similarly raised as shown in Fig.
2c. It
as will be seen that each end panel section 14 carries an in-fill panel
section 13a. It will
also be seen that the leg members 25 are not as thick as the joining members
21 such
that they may lie unobtrusively between frame side members 19 joined by the
joining
members 21.
As illustrated in Fig. 2d, the rear one of the side wall panel sections 14 is
then
3o pivoted to its operative position and the rear wall panel is completed by
hinging the infill
panel sections 13a to join the side wall panel section 14 to the end wall
panel sections
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14. Thereafter as shown in Figs. 2g to 2i, the front wall panel section 12 is
raised and
infill panel sections 13b suspended therefrom are pivoted to their operative
positions to
complete the perimeter wall frame about the floor panel section 15.
It will be seen that the wall panel sections 14 terminate inwardly of the leg
s members 25 and couple to the floor panel section 15 through joining members
21 bolted
to the outer side face of the web 24 and adapted in the erected position to
transfer
vertical loads directly to complementary lower joining members which are also
through
bolted to the web 24 but extend upwardly from telescopically adjustable
intermediate
posts 28.
io The hinge detail enabling the wall panel sections 12 to pivot from their
stowed
position to their operative supporting position are illustrated in Fig. 6.
The joining members 21 are formed from the same hollow rectangular section
and are open along their underside for location about the upwardly converging
deflector
members 30 mounted along the upper end of the joining members 21. The upper
is joining member 27 illustrated in Fig. 4 s a composite member having
substantially
identical upper and lower sections 27a and 27b interconnected through a welded-
in bar
31. The upper section 27a is provided with spaced threaded apertures 32
adapted for
through bolting to the apertures 33 formed in the open corner member 34 of
each wall
panel section 14.
2o The corresponding threaded apertures 32 in the lower composite joining
members 27 are bolted to the web 24 through vertical slots 35 formed in the
web 24 as
illustrated in Fig 4a. The open corner members 34 terminate each frame side
member
19 of the wall panel sections 14 and enable rigid through bolting to joining
members 21
and 27.
2s As illustrated in Fig. 4a, in order to permit the lower of the stacked wall
sections
14 to be raised pivotally its their upright position, it pivots about the bolt
which passes
through one of the apertures 33 in the open corner member 34 to engage
threadedly in
the innermost one of the threaded apertures 32 of the upper portion 27a. Thus
the side
panel sections 12 may be pivoted about these opposed engaged bolts until the
other
3o aperture 33 aligns with the adjacent threaded aperture 32 in the upper
portion of the
joining member 27 when the wall is vertical, enabling the bolted connection
through the
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open corner member 34 to be completed.
At the same time, the slotted apertures 35 for the bolts securing the lower
portion
27a permit that portion to move downwardly to nest against the upper end of
the joining
member 21 secured to the post assembly 26, as illustrated in Fig. 4b. The four
bolts
s holding the upper and lower sections of the joining member 27 to the side
frame
member 19 and the open corner member 34 of the side pane! section 12 may then
be
tightened to effect the joint between the side panel section 12 and the floor
panel section
15. ,
It will also be seen that each infill panel section 13 is hinged by upper and
tower
to two part drop hinges 36 which are removable once the bolted connection is
effected to
the frame side members 19 of the side panel section 12. The hinges 36 permit
the infill
panel sections 13 to be pivoted to an in-line position accompanied by a
dropping action
at full pivot at which the upper leaf clears the blocking projection such that
the apertures
33 in the open corner member 34 of the infill panel section i 3 align with the
apertures 32
is in the upper part of the joining member 27. In this manner the infill panel
sections 13
are rigidly bolted to the side panel section 12 through the upper part of the
joining
member 27. This sequence is illustrated in Fig 4a, 4b, 4c and 4d.
The joining member 27 at the upper end of the adjacent side frame members 19
is initially bolted to the infill panel section 13 through a single bolt 39
whereby it may
2o rock to and from about this bolted connection to the upper open corner
member 34 for
the purpose which will hereinafter become apparent. Also, the upper portion of
this
joining member 38 is relatively wide to provide for side by side bolted
connection of the
adjoining ceiling frame sections thereto.
An alternate hinging arrangement between the rear infill panels 13 and the end
2s panel sections 14 is shown in Fig. 7. These pivotal connections 41 are
simple pin
connections bolted into the corner members 34 providing vertical pins 42 which
engages
in the open upper end of the adjacent infill frame side member. As the infill
panels 13
pivot outwardly to their operative position, they must pass across the flange
44 of the
floor side frame member 19F before dropping to their operative bolted
positions. Thus
3o the upper and lower hinges 41 are configured as drop hinges permitting this
downward
movement at the full pivot position.
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Each infill panel section 13 is maintained in its elevated position by a
blocking
section 45 fixed to the underside of its side frame member 19. In their
operative
positions, the infill panels at the rear side panel sections are secured in
this same
manner as those at the front and previously described.
s After the walls have been secured in position about the floor panel section
15 with
the upright side frame members 19 forming load paths having upper and lower
joining
members 21 /27 for receiving and transferring loads direct from the roof to
the support
posts 28, the roof module 11 R is craned into position to rest on the upper
edges of the
wall panel sections. This and the subsequent sequence of erection is shown in
Figs. 2k
to to 2m.
Fig. 5 illustrates the arrangement of supporting posts 28 and their integral
joining
members 21 to provide a structure having double internal walls separated by an
air gap
providing four separate accommodation modules. Thus the centre post 28c has
four
joining members 21 as illustrated in Fig. 5b and the intermediate end posts 21
i have
is opposed joining members 21 as illustrated in Fig. 3c.
Referring to Figs. 2i to 2m, it will be seen that the roof module 10r includes
three
roof and ceiling panel sections each having frame side members 19 which bolt
to the
joining members 21/27 interconnecting the wall panel sections 12 and the
infill panel
sections 13. This arrangement provides direct vertical load paths to the
supporting
Zo posts through the composite posts formed by the interconnected frame side
members,
with free spans therebetween.
As the ceiling panel sections 16 fit closely between the front and rear
joining
members 27 these members may be to pivoted outwardly during placement of the
ceiling panel sections to permit them to pass downwardly therebetween to their
2s operative positions whereupon the joining members 27 may be pivoted
inwardly to an
upright position and be securely bolted to the ceiling panel section 16.
Furthermore, the
joining members 21 for the front corners of the floor modules 11 F and ceiling
pane(
sections 16 are positioned on the pivotable infill panels 13 at the front such
that they
may swing outwardly to a slight degree to permit the ceiling panel section 16
to be
3o installed before final bolting together in their operative position in a
similar manner to the
joining members 27.
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Referring to Fig. 8 it will be seen that the roof panel sections 17 are
initially
disposed with their inner edges 38 adjacent one another above the centre line
of the
structure. They also carry verandah panel sections 50 hingedly connected to
their outer
ends by removable hinges 53 and stowed in an overlying attitude above the roof
panel
s sections 17. One of these panel sections 17 is moved inwardly beyond the
centreline
position so that its outer end may be connected to a spaced joining members
21/27,
disposed between and interconnecting ceiling panel sections 16, by one bolt in
each to
form a hinge point about which that section may be raised.
The apex brackets 51 are bolted in place and the opposing roof panel section
17
to is then moved inwardly over the top of the connected panel section 17. Both
roof panel
sections 17 are then elevated so that the upper ends 54 of some of the side
frame
members 19 of the uppermost roof panel section 17 is trapped upon moving over-
centre
to form the ridge as illustrated in Fig. 12b. Thereafter, the verandah panel
sections 50
are pivoted outwardly on the removable brackets 53 before finally being
secured in
is place with fixed brackets 52 as illustrated in the detail to the exposed
upper portions of
the joining members 21.
As shown in Fig. 9, the trap arrangement 55 comprises respective camming
surfaces 47 on the apex brackets 51 and base plates 65 upon which the ends 38
of the
adjacent uncoupled but spaced side frame members 19 will rest upon capture.
2o Thereafter they are through bolted at 47 to the apex bracket 51 to complete
the upper
cord of the truss.
Bracing members 46 are also bolted into the gap between adjacent end frame
side members 19 of the ceiling panel sections 16 and the roof panel sections
17 to form
trusses in line with the supporting posts such that all roof loads are
transferred directly
2s along the vertical load paths to the supporting posts.
In order to provide a floor structure which has adequate strength for spanning
between opposed side walls and which is economical to manufacture and
transport, the
floor panel section 15 as illustrated in Fig. 6 is formed as a ladder frame in
which the
frame frame side members 19 and the rung members 20 are formed as open C-
section
so members. The frame side members 19 are provided with upper and lower pairs
of
apertures 66 at each end for through bolting to the lower joining members 21
on the end
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posts and intermediate pairs of apertures 67 and slots 35 for securing these
members
above the intermediate post 28i.
It will be seen that the verandah floor panels 60 rest upon the same foot
plate 62
which supports the floor panel section but it is constructed of shallower open
frame
s sections to provide the necessary step down to the verandah floor.
It will be seen in the exploded view that the web portion 70 of each rung 20
is
scalloped at its ends at 71 to provide upper and lower mating end portions
which are
welded to the flanges 44 of the frame frame side members 19. Vertical bracing
members 72 extend between the flanges 44 intermediate the respective pairs of
to apertures 66 and slots 35 to reinforce the vertical load path through the
side frame
members 19. This is clearly illustrated in Fig. 6b which illustrates a fillet
welded version
of the floor frame.
The spot welded version of the floor frame is illustrated in Figs. 6e to 6g
and it will
be seen that extra reinforcing pieces 73 which co-operate with a formed end
portion 74
is of the rung member 20 so as to provide the necessary rigid spot welded
connection of
the rung members 20 to the frame frame side members 19.
It will be seen that the structure 10 can be assembled from four prefabricated
floor modules 11f and roof modules 11r to form four separate accommodation
units,
separated by double walls with air gaps therebetween, which can be quickly
erected as
2o described in relation to the illustrated embodiment above and, if desired,
with the floor
being placed by a crane according to the method described above to facilitate
fast and
simple erection by unskilled labour.
While the structure is shown with open frames, these frames can be pre-clad in
the factory for erection of prefabricated structures to the lock up stage
without the need
2s for on-site fabrication.
The hinge mechanism 80 illustrated in Figs 11 a to 11 c provides a separate
hinging arrangement whereby side by side wall panel sections 14 can be pivoted
to an
upstanding attitude from an overlying attitude. Each hinge mechanism 80 is
formed
from a connector plate 81 provided with a spacing leg 82 as per the previous
3o embodiment which extends to a pin type pivot 83. The connector plate 81 is
provided
with upper and lower pairs of threaded apertures 84.
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The upper pair of threaded apertures 84 are bolted to the wall frame side
members 19 and the lower pair extend below the wall panel section 14 for
alignment
with the complementary apertures 86 formed in the side members 19 of the floor
panel
sections 87. The lower pair are through bolted when erected to secure the wall
frame
s side members to the floor frame side members which, in use, are connected by
the
joining members 21 to an adjacent floor frame side member. The lower ends of
the
connector plates wedge behind the deflector members 30 and the joining members
21
provide the indirect interconnection of adjacent wall frame side members 19.
The use of such joining members 80 enables a row of wall panel sections to be
io raised and interconnected in succession to form a wall panel. Further, as
illustrated in
Figs. 12, the cladding on the wall panels which includes an inner skin 90 and
an outer
skin 91 is provided with offset lateral extensions 92 and 93 from the opposing
wall frame
side members 19. Thus the outer extension 93 of one panel provides an abutment
for
the partly exposed outer edge 94 of the adjacent wall frame side member 19 as
it is
is raised to its upstanding attitude. At the same time, the offset inner
extension 93 of that
adjacent panel simultaneously abuts the partly exposed inner edge 96 of that
one panel.
This enables each skin 90 and 91 to be screwed or otherwise attached to the
frame side
members 19 of the adjacent wall frame side members 19 which facilitates an
flush joint
being formed between the skins of the panel sections.
2o The panels may be shipped with the services connected, being per-wired in
conduits and with plumbing installed. As illustrated in Figs 13a to 13c, the
wiring
conduits include upper and lower arcuate tubular portions 100 and 101 fixed to
respective ones of the wall and floor panel sections 14 and 15 which pivot
from an
overlying attitude as per Fig. 13b to a standing attitude as per Fig. 13c. The
pivoting
2s occurs about a pivot pin 102 shown in the exploded view of Fig. 13a. The
complementary arcuate tubes are slidably engaged with one another and are
positioned
concentrically with the wall hinge axis through the pins 102 for sliding
engagement as
the wall pivots between its stowed and standing attitude. Cable slackness in
the
conduit which may result from such concertina movement may be drawn out at the
wall
so or floor ends of the conduits.
The water conduit assembly 104 has a similar upper conduit 106 terminated at
its
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free end by a threaded coupling 105 which is pivoted into an operative
substantially
abutting alignment with a mating connector 103 in the floor cavity through an
access
aperture 107. The connection can thus be readily made once the wall panel
section 14
is positioned and/or bolted in its upstanding attitude. All the conduits are
set in from the
s outer wall cladding 91 so that it is concealed by the downward extension 108
of the
external cladding in the erected attitude.
The adjustable support assembly 28 includes a length adjustable leg 111
supported by a foot assembly 112. The leg 111 includes upper and lower
cylindrical
members 113 and 114 which engage telescopically with respect to one another
and
io which are through bolted by bolts 115 for length adjustable interlocking
engagement with
one another. The lower end portion 114 is loosely connected to the foot
assembly 112
by the captive engagement of a transverse pin 116 extending through the
opposite side
walls of the lower portion 114 and through a relatively broad loop 117
extending
upwardly from and fixed to the foot assembly 112.
is
The engagement of the pin 116 in the loop 117 is such that the engagement does
not prevent relative rotation of the foot assembly and the leg assembly about
the
longitudinal axis of the leg assembly through a wide range of adjustments in
the order of
15°. Furthermore, it will be seen that the loop 117 extends upwardly
from the crest of a
2o dome portion 120 disposed substantially centrally in the rectangular plate
like foot
assembly 112.
The outer planar portion 121 of the base plate is provided with bolt apertures
122
in each corner. It will also be seen that the captive connection of the pin
116 by the loop
is 117 permits a substantial extent of axial movement of the leg assembly
relative to the
foot assembly such that in addition to the relative axial rotation the captive
mounting of
the pin 116 within the loop does not inhibit support of the leg assembly on a
portion of
the domed portion 120 offset from the crest at any position therearound.
so Thus, within the range of allowable adjustments of the support assembly,
the
base plate 121 may be supported on an inclined surface such as the ground or
the
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upper end of a bored footing to which the foot assembly is connected by
through bolting
through the apertures 122 and the leg assembly may be adjusted to lie in a
vertical
plane with axial loads thereon being transferred through the annular bottom
face of the
lower portion 114 engaged fully with the corresponding portion of the dome
portion 120.
s
Infinite height adjustment within the range of adjustment of the support
assembly
is provided by arranging vertically spaced slots 125 in the larger upper tube
113 having
a length equal to the distance between the equally spaced threaded apertures
126 in the
inner tube 114. Locking in the selected adjustment is achieved by inserting
the bolts
io 115 through the slots 125 into the appropriate threaded apertures 126 and
tightening the
bolts to clamp the inner tube to the outer tube upon the selected adjustment
length
being achieved.
For the purposes of a building foundation after initial adjustment has been
is achieved, both lengthwise and in order to secure the post in a vertical
orientation, the
bottom face of the lower tube 114 may be welded to the domed portion 120 and
if
desired the outer tube 113 may be welded to the inner tube 114 about their
junction.
The upper end of the upper member 113 is closed by a plate 127 upon which is
mounted a hollow rectangular sectioned joining member 21. This member 123 is
2o provided with rolled thread connections 129 formed in the opposing side
walls 130 in an
operation in which metal is forced inwardly to form a threaded open socket
having a
depth much greater than the wall thickness of the joining member 21 the
deflector
member 30 is welded across the open top of the joining member 21.
2s The task sequence of Figs. 14/1 to 14/32 illustrates erection of a
structure utilising
the alternate features of Figs. 11 to 13. The paragraph describing each task
commences with the drawing suffix number and the estimated time sequence for
performing the tasks.
14/1. TIME: 0 Hrs, 0 Mins: The truck carrying the full building module
so arrives at site. Screw-in-foundations are installed using a hydraulically
driven power
head attached to truck crane jib, which carries the modules. Alternatively,
screw-in-
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foundations can be installed in advance. Bored concrete piers can be used
instead of
Screw-in-foundations.
1412. TIME: 1 Hrs, 20 Mins: Once the screw-in-foundations installation is
complete, the site is ready for erection of the modules.
s 14/3. TIME: 1 Hrs, 25 Mins: The first floor/wall module is unloaded and held
elevated by the crane sling.
14/4. TIME: 1 Hrs, 30 Mins: The self leveling support posts are attached
while the frame is elevated still in the sling.
14/5. TIME: 1 Hrs, 35 Mins: The module is craned over the screw-in-
to foundation's, self leveling footing's are dropped down to the screw-in-
foundation's, and
temporary adjustment bolts tightened up. The outer telescoping tube of the
self leveling
footing finds its own level, and the "footing plate", with its convex upper
face, will sit flat
on top of the screw-in-foundation, even if it is not installed vertically. The
first installed
floor/wall module provides a datum for the remaining floor/wall modules. Once
this
is frame is level, all of the other frames have only to be leveled on one
side, since the
frame-side closest to the already leveled frame sits on top of the leveled
self leveling
footing. The next frame is unloaded.
14/6. TIME: 1 Hrs, 50 Mins: The last main floor frame is in position. Ideally
the module should be erected down one side first to ensure that SCREW-IN-
2o FOUNDATION's have been installed correctly they can be reinstalled.
14/7. TIME: 1 Hrs, 55 Mins: The verandah frame is craned into position and
bolted off.
14/8. TIME: 2 Hrs, 0 Mins: All floors are in position, their level is checked.
The first wall to be folded up is an inside blank frame-end "dry" wall, so
called because is
2s does not form part of a wet area. It is bolted off. The next series of
steps takes place
from right to left, back of module to front.
14/9. TIME: 2 Hrs, 5 Mins: The opposite frame-end window wall is
unfolded, and bolted off.
14/10. TIME: 2 Hrs, 10 Mins: The sequence in Fig. 14i is repeated. The bay-
3o end window wall is attached to the frame-end blank dry wall. There is a
double "sound
proof" wail along the common room axis in this module, hence there are two
inside blank
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frame-end walls.
14/11. TIME: 2 Hrs, 15 Mins: The front facing frame-end window wall is
folded up.
14/12. TIME: 2 Hrs, 20 Mins: The back verandah frame is folded up. It has a
s telescoping section allowing it to be extended up to 2450mm when upright,
but sit over a
2200mm wide frame when flat-packed.
14/13. TIME: 2 Hrs, 30 Mins: Both sets of ceiling-verandah-main roof
assemblies are craned in. The roof frames have a three-way acting connector
plate
which allows the roof frame to move inboard and outboard of the ceiling frame,
zo establishing an overlap. A boomerang shaped plate with a "trap" allows
opposing roof
frames to be pushed up in one action. When fully deployed at the correct angle
of roof
pitch the connector plate locks the frames together, which are then bolted
off.
14/14. TIME: 2 Hrs, 35 Mins: Both roof frames are pushed up, either with an
air-bag, a pneumatic jack or by crane. The front veranda frame is folded up.
zs 14/15. TIME: 2 Hrs, 40 Mins: The truss web is bolted into place, and the
verandah posts telescoped up.
14/16. TIME: 2 Hrs, 45 Mins: The verandah roof is rotated into position. This
completes the first segment of construction. The next wall to be unfolded is
an internal
blank frame-end wet/dry wall.
20 14/17. TIME: 2 Hrs, 50 Mins: The back facing frame-end blank wall is
unfolded, and bolted off. Plumbing connections are completed from the back of
walls to
the under floor area. The opposing frame-end window wall is unfolded. The pre-
fixed
electrical loom is connected between walls that have power outlets, switches
or lights.
14/18. TIME: 2 Hrs, 55 Mins: The back facing frame end-wall is upright, and
2s bolted off.
14/19. TIME: 3 Hrs, 0 Mins: The front facing frame-end blank wet/dry wall is
unfolded. This shows the blank bay-end frame folded inside of it.
14/20. TIME: 3 Hrs, 5 Mins: The front frame-end window/door wall is folded
up.
30 14/21. TIME: 3 Hrs, 10 Mins: Ceiling-verandah-main roof assemblies are
craned in.
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14/22. TIME: 3 Hrs, 15 Mins: The roof is folded up, and truss webs bolted off.
14/23. TIME; 3 Hrs, 20 Mins: The frame-end blank wet-dry wall is folded up.
14/24. TIME: 3 Hrs, 25 Mins: The opposing frame end window/door wall is
folded up.
s 14/25. TIME: 3 Hrs, 30 Mins: The verandah frame is rotated up.
14/26. TIME: 3 Hrs, 35 Mins: Ceiling-verandah-main roof assemblies
are
craned-in.
14/27. TIME: 3 Hrs, 40 Mins: Verandah roof frame is rotated over.
14/28. TIME: 3 Hrs, 45 Mins: The last segment of wall frames is
rotated up,
io and bolted off.
14/29. TIME: 3 Hrs, 55 Mins: Ceiling-verandah-main roof assemblies
are
craned in.
14/30. TIME: 4 Hrs, 10 Mins: Roof frames are folded up and gable
end
trusses are bolted in.
is 14/31. TIME: 4 Hrs, 20 Mins: The gable end piece is added, and hydraulics
connected. Stairs are added.
14/32. TIME: 4 Hrs, 25 Mins: The module is ready for finishing off.
The above times are given as a guide to illustrate that a structure
according to
this invention may be erected atically and rapidly and are not intended
system as actual
2o times which can be achieved.
