Note: Descriptions are shown in the official language in which they were submitted.
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PATENT APPLICATION
TITLE OF THE INVENTION
ALUMINUM ACCOMMODATIONS MODULE AND METHOD OF CONSTRUCTING
SAME
INVENTORS: DESORMEAUX, Thomas, F., a US citizen, of 17171
Highland Road, Baton Rouge, LA, 70810, US; and
STAKES, George, Shea, a US citizen, of 7531 West
Cougar, Abbeville, LA, 70510 US.
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a non provisional patent application of US
Provisional Patent Application Serial No. 61/372,922, filed 12
August 2010.
Priority of US Provisional Patent Application Serial No.
61/372,922, filed 12 August 2010, hereby incorporated herein
by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
Not applicable
REFERENCE TO A "MICROFICHE APPENDIX"
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to modular construction of
buildings. More particularly, the present invention relates to a
modular building constructed of Aluminum wherein the interior and
exterior walls are constructed as to not be connected, which
allows fire insulation blanketing therebetween to be a prime
barrier to potential fire hazards.
2. General Background of the Invention
In the marine transport and vessel regulation environment,
the USCG is charged with regulating the materials and methods by
which industry must conform in order to have a safe working
environment for personnel. Other similar governing agencies in
the world are the ABS (American Bureau of Shipping), DNV De
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Norske Veritas and Lloyds Regulations which are also known as
SOLAS (Safety of Life at Sea). Many of the regulations in place
today stem from meetings of the world shipping organizations in
the 1912 and 1970's. Many of the early regulations came as a
result of the Titanic catastrophe.
Historically, modular marine buildings exteriors have been
constructed out of steel, which is quite heavy. There is a need
in the industry for a modular marine building to be constructed
of lightweight material, such as Aluminum, and in such a manner
that the building is vastly more safe against fire hazards.
BRIEF SUMMARY OF THE INVENTION
The present invention solves the problems in the art in a
straightforward manner. What is provided is a modular building
and a method of constructing a United States Coast Guard (USCG)
certified modular building for utilization on USCG approved
vessels, as well as vessels under foreign flags, ABS, NV, and
other regulating agencies, out of aluminum and special Firemaster
Marine Blanketing material. Under the method of the present
invention, the walls are constructed as to not be connected,
allow the fire insulation blanketing to be a prime barrier to
potential fire hazards. Due to several reasons aluminum can be a
better material than steel to utilize for the purpose of marine
accommodations. First, Aluminum is considerably lighter, due to
the crane capacities on offshore floating platforms and boats,
the lighter the building the safer it is to lift. Also, the
lightweight on vessels serves to lighten the overall load
reducing fuel consumption considerably. Aluminum exterior
buildings can weigh half of what steel buildings do. Second and
equally important is that aluminum does not corrode (oxidize)
nearly as fast as steel in a salt laden marine environment.
Therefore, it is not necessary to install elaborate coating
systems to try to protect the exterior of the aluminum buildings
as must be done on steel buildings making the aluminum buildings
much more maintenance friendly.
The design criteria that is novel and sets this as an
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original invention, is the method by which the building is
constructed with one interior structure separate from the
exterior structure, thus making it virtually a building inside of
a building. The insulation utilized is a blanket that meets all
criteria of the USCG for exterior (A-60 fire rating) on its own.
Thus, by having the interior walls being able to stand alone,
then covered by the fire blanket insulation, this alone would
constitute a safe environment for lodgers. Along with this, an
external wall is added, (which is light weight as well) aluminum,
just to protect the fire wall blanket insulation from the
exterior environment and to provide more structural safety for
the building. Another added benefit to having the dual wall
system is that it will provide even more air space for increase
insulation benefit for greater efficiency for heating and cooling
the building. Applicants have designed and engineered a
revolutionary method to have a certified, safe, and lightweight
exterior wall design that can be utilized to construct all types
of buildings for deepwater structures, marine vessels, and other
floating structures. The design can be used to build USCG
certified accommodations, MCC's, offices, and other manned
structures of all sizes. The wall design meets A-60 or H-60 fire
ratings. It can be engineered to have a blast rating of as much
as 1.5 bar static loading. The dual wall design has better
insulation properties for increased protection from fire, heat,
cold, and sound. The design can be utilized to save up to half
of the weight of conventional structures, whether it be a small
modular building or a large multi-story single lift building.
Applicants' new USCG building is nearly half the weight of
conventional steel buildings.
12 Man Sleeper Building (Aluminum) 12'0" x 40'0" (3.7 m x 12.2 m)
24,800 lbs. (11,249 kg)
12 Man Sleeper Building (Steel) 12'0" x 40'0" (3.7 m x 12.2 m)
48,000 lbs. (21,772 kg)
Offshore Oil and Gas Operators understand the advantage of
reduced weight, from loading, unloading, transportation, safety
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and platform limitations.
Steel 3/16" (0.48 cm) thickness weighs 7.6 lbs/sq ft (37.1 kg/sq
m).
Aluminum 3/16" (0.48 cm) thickness weights 2.7 lbs/sq ft (13.2
kg/sq m).
The many objects of the present invention are presented
below:
A principal object is that Applicants' new building is
constructed out of aluminum which does not need a coating system
to ward off salt laden environments. The building's exterior is
crimped plate aluminum and does not corrode in salt laden
environments, making the building less costly and dangerous over
time. Steel structures will eventually develop rusting and
leakage, leading to dangerous moisture intrusion, along with
compromised structural integrity, it can develop mold and
bacteria growth making interior living spaces uninhabitable.
Because of LQT's dual wall system design, even if there is a
breech in an exterior wall the interior space is completely
sealed and independent from the exterior wall, making it nearly
impossible to have moisture intrusion. Over time the reduced
maintenance cost will pay for the entire structure. It also has
a considerably longer life cycle.
CORROSION RESISTANCE OF ALUMINUM
A second principal object is that Applicants' building has
corrosion resistance of Aluminum. According to engineers,
Aluminum has excellent corrosion resistance in a wide range of
water and soil conditions, because of the tough oxide film that
forms on its surface. Although aluminum is an active metal in
the galvanic series, this film affords excellent protection in
salt water environments.
HIGH BLAST RATING CAPABILITY
Another principal object is that Applicants' building has a
high blast rating capability. The new design allows for a
lightweight answer to the ever increasing safety concerns of
catastrophic blasts. The new wall design can be engineered to
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increase blast ratings from as little as .1 bar (10 kPa) to 1.5
bar (150 kPa) and still maintain the lightweight dual wall
design. Due to the fact that the wall design is two completely
separate walls, with no interconnecting parts, the exterior wall
serves as a blast wall, while the interior wall remains
structurally sound. This allows the design to have considerably
higher protection against blast, making the interior much safer
for the occupants. The new USCG/ABS Rental/Sale building wall
design is .25 bar (25 kPa) blast certified.
IMPROVED INSULATION DESIGN
Another principal object is that Applicants' building has
improved insulation design. The new dual wall design incorporates
a 3' (0.9 m) thick layer of Firemaster A-60 insulation blanketing
the entire building. The insulation is tested at extreme
temperatures to offer protection from open flames, but along with
it's fire protection capabilities, the insulation has a very high
R factor when combined with the 4" (10 cm) airspace in the wall
design. Air is the best insulating material. In addition to
this, the air in the space, is circulated through the buildings
HVAC system, for added heating and cooling benefits.
IMPROVED SOUND REDUCTION DESIGN
Another principal object is that Applicants' building has
improved sound reduction design. The wall design and interior
products discourage noise pollution. Along with the inside wall
air space the insulation provides noise reduction capabilities.
The building reduces sound decibels by as much as 30% over the
conventional steel building single wall design. This obviously
makes the building more comfortable for its occupants.
INTERIOR DESIGN STATE OF THE ART
Another principal object is that Applicants' building has
state of the art interior design. The interior components are
all state of the art fire safe comfortable and USCG approved
materials. Living Quarter Technology has years of experience
providing accommodations to the Offshore oil and gas business.
The company provides pillow top mattresses with oversize bedding
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along with comfort quiet curtains for privacy. The building has
oversized HVAC capacity for heating and cooling in extreme
environments. All the latest safety features are incorporated in
the unit, including fire and gas detection systems and smoke
detection. The system has emergency lighting that maintains full
lighting throughout the building in case of loss of power.
LOWER OVERALL COSTS OF CONSTRUCTION
Another principal object is that Applicants' design has
lower overall costs of construction. Although the costs of
aluminum is a little higher than raw steel, due to the fact that
the building does not need to have a coating system, the overall
capital costs of the building is approximately 10% less than a
conventional similar steel building. This along with the fact
that the building has better insulation properties and lower
maintenance costs, easily make it a better overall value.
23,200 lbs (10,523 kg) Lighter
Another principal object is that Applicants' building is
much lighter than conventional offshore buildings. Offshore Oil
and Gas Operators understand the advantages of reduced weight
from loading, unloading, transportation, safety and platform
limitations. Nearly have the weight of conventional steel
buildings: compare our aluminum 12-man-sleeper at 24,800 lbs
(11,249 kg) to a steel 12-main sleeper at 48,000 lbs (21,772 kg).
Low Maintenance
Another principal object is that Applicants' building's
exterior of crimped plate aluminum does not corrode in salt-laden
environments, making the building less costly, safer, and giving
it a considerable longer life cycle. Over time the reduced
maintenance cost will pay for the entire structure. Because of
LQT's dual wall system design, even if there is a breach in the
exterior wall, the interior space is completely sealed and
independent from the exterior wall, making it nearly impossible
to have moisture intrusion.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and
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advantages of the present invention, reference should be had to
the following detailed description, read in conjunction with the
following drawings, wherein like reference numerals denote like
elements and wherein:
Figure 1 illustrates a top view of the living quarters
component of the modular aluminum modules in a preferred
embodiment of the present invention;
Figure 2 illustrates a top view of the outer protective
shell component of the modular aluminum modules in a preferred
embodiment of the present invention;
Figure 3 illustrates a partial corner view of the insulation
enveloping the living quarters in the modular aluminum modules of
the present invention;
Figure 4 illustrates a top view of the composite
accommodations module of the present invention where the outer
protective shell has been positioned over the living quarters
component;
Figure 5 illustrates a plurality of six accommodations
modules of the present invention positioned in a single group for
occupation by workers;
Figures 6 through 8 illustrate views of the anchor system of
the present invention which engage modules stacked upon one other
to avoid upper modules from disengaging from the modules below;
Figure 9 illustrates a top view of the roof framing plan of
the modules of the present invention;
Figure 10 illustrates a top view of the floor framing plan
of the modules of the present invention;
Figures 11 through 14 illustrate the corner construction
between the outer protective shell and the inner housing quarters
in the module of the present invention;
Figures 15A and 15B illustrate the dynamics involved when
the outer protective shell is impacted by a blast impacting a
module of the present invention;
Figure 16 illustrates an additional view of the wall
construction interconnecting with the floor of a module of the
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present invention;
Figures 17 and 18 illustrate views of the attachment of the
lifting padeyes which are engaged when lifting a module of the
present invention; Figure 17 illustrates a top view of the
reflective ceiling plan of the present invention;
Figures 19 through 21 illustrate additional views of the
manner in which the insulation blanket is secured to the outer
surface of the living quarters wall in the present invention;
Figures 22 and 23 illustrate cross-section views of the air
flow system and the manner of insulation in the module of the
present invention;
Figure 24 illustrates a top view of a typical the six-man
galley of the present invention; and
Figure 25 illustrates a partial top view of the module of
the present invention where the insulation is positioned to the
exterior of the four corner posts, so that structural corners
supporting an upper building are inside the insulation blanket to
prevent destruction by fire, blast or other catastrophic event.
DETAILED DESCRIPTION OF THE INVENTION
Figures 1-25 illustrate a preferred embodiment and the
modular accommodations module and method of erecting same in the
present invention. First, in a discussion of the overall
invention, reference should be first made to Figures 1-4 which
illustrate the accommodations module 10 (hereinafter called
module 10), which comprises an interior living quarters 12
constructed of aluminum placed within an exterior protective
shell 14, which is also constructed of lightweight aluminum, with
the walls of the exterior protective shell 14 having no contact
whatsoever in the wall space there between.
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As seen first in Figure 1, there is illustrated the
substantially rectangular interior living quarters 12 having a
pair of parallel side walls 17 and 19 and end walls 20 and 22
with doorways 24 therein. There is further provided a ceiling
portion 26 and a floor portion 28, all of which define the
interior living quarters 12. As stated earlier, the four walls,
ceiling and floor of this living quarters 12 would be constructed
of a lightweight aluminum and welded together as a single unit so
that it would form a continuous non-interrupted aluminum shell 30
defining the living quarters 12 there within. As illustrated,
the walls of the living quarters 12 would be held in place with a
plurality of vertical C beams 15 along the walls, and the floor
28 would be raised above the ground when the living quarters 12
is resting on the ground.
In Figure 2, there is illustrated the exterior protective
shell 14, constructed of lightweight aluminum sheets 23, and
being of a length and width larger than that of the living
quarters 12, for the reasons to follow. The aluminum sheets 23
would form a pair of side walls 32 and 34, end walls 36 and 38
with doorways 40 which would line up with the doorways 24 of the
interior living quarters 12. The exterior protective shell 14
would likewise include an upper roof 42, which together with the
side walls and end walls would define the protective shell 14
enclosure. It should be noted that the aluminum sheets 23 extend
the entire height of the side walls 32, 34 and end walls 36, 38,
as seen in Figure 5, for reasons to follow. The walls of the
protective shell 14, would also be held upright with a plurality
of spaced apart C beams 35, slightly larger in size than the C
beams 15 supporting the walls of living quarters 12.
In Figure 3, there is illustrated a section of insulation 50
of the type preferably having A-60 fire rating, that was
discussed earlier in the application. The insulation 50 would be
placed along the entire outer surface 52 of the sidewalls 17, 19,
end walls 20, 22, ceiling 26 and floor portion 28, of the living
quarters 12, so as to define a continuous layer of insulation 50
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enveloping the entire living quarters 12. It is critical that the
entire outer surface of living quarters 12 be covered by the
continuous layer of insulation 50. Following the enveloping of
the living quarters 12 with insulation 50, as seen in Figure 4,
because the living quarters 12 is of smaller dimensions than the
exterior protective shell 14, the shell 14 would be lowered down
upon the living quarters 12, so that the protective shell 14
would completely envelope the living quarters 12, and the lower
ends of the walls of the protective shell 14 would extend to the
very lower edge of the walls of the living quarters 12. Once the
protective shell 14 is in place over the living quarters 12, this
would define the composite module 10, and would cover the
structural skid beams for greater stability in case of a fire or
blast event.
It is of critical importance as seen in the Figures, that
the insulation 50 and C beams 15 which are surrounding the
interior living quarters 12 make no contact whatsoever with the C
beams 35 on the inner surface 33 of protective shell 14, as seen
in Figure 3. This is possible because of the larger dimensions
of protective shell 14. Therefore what is defined is a
continuous air space 60 entirely surrounding the walls and
ceiling of the living quarters 12 and the walls and ceiling of
protective shell 14. This air space 60 is critical, as will be
explained further.
Turning now to Figure 5, there illustrated a front view of a
series, in this case, six modular units 10, two of which have
been set side by side and four which have been stacked thereupon
to form the composite six unit living quarters 12 therewithin.
It should be noted that each of the side walls 32, 34 and end
walls 36, 38 of each module 10 are formed of exterior aluminum
panels 23 which extend from the upper point 25 of each module 10
to the lower most point 27 of each module 10. This is critical
since this aluminum protective shell 14 would allow no heat nor
any kind of force to contact the inner air space 60 between the
outer walls of the protective shell 14 and the walls of the
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interior living quarters 12 without contacting first the aluminum
sheets of the walls of the protective shell 14, and all main
structural beams for greater stability in hazardous conditions.
It should also be noted in Figure 5 that there is shown a
group of six modules 10, the group being a lower pair of modules
supporting two pairs of modules 10 thereupon. First, there is
illustrated a plurality of exterior bolting connections 64
between the two lower side by side modules 10 of the six, and the
two pairs of upper modules 10 resting on the lower modules 10.
10 As seen in Figure 5, and as discussed more in detail in
Figures 6 through 8, the upper most pair of modules 10 each
include a plurality of upright anchor members 66, which are
extending out from the roof 42 of each of the modules 10.
Likewise, the floor 28 of each module 10 would have a plurality
of corresponding recesses 68 so that when a module 10 is placed
upon a lower module 10, the upright anchor members 66 are each
stabbed into a corresponding recess 68 of the upper module 10, so
that the upper module 10 is held firmly in place atop the lower
module 10. For purposes of safety, it is critical to note that
the anchor members 66, which are shown in position on the roof of
a module 10 in Figures 5 and 7, are positioned on the upper
surface or roof of each of the modules 10 at points interior to
the walls of the living quarters 12. Through such placement, the
connections between the upper and lower modules 10 will not be
compromised by heat or blast, which if they were not, may result
in the collapse of the outer edge of the protective shell 14, and
result in the upper module 10 toppling off of the lower module
10.
As seen in detail in Figures 6 through 8, there is a view of
a typical anchor member 66 which extends upward from the roof of
each of the modules 10. There is seen a base plate 72 wherein
the vertical anchor member 66 extends upward which would fit into
a recess 68 of the module 10 above it. It is seen that when the
uppermost anchor member 66, as seen for example in Figure 5, will
have no module 10 placed thereupon; therefore, there is
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positioned an insulated cap 76 which would fit on to the anchor
member 66 so that should heat engage the exterior of the module
in the course of a fire or blast, the heat could not travel
through the anchor member 66 down into the living quarters 12.
5 The insulated cap 76 would prevent the heat from gaining access
there through. Of course when a module 10 has a second module 10
stacked upon it, the heat cannot get into it so it would not need
an insulation in that regard.
Figures 9 and 10 are views of the roof framing plan and
10 floor framing plan, respectively. It should be noted in Figure 9
that the anchor members 66 are shown in the four corners of the
composite module 10 again, as stated earlier, with each of the
anchor members 66 being set interior to the walls of the living
quarters 12, to avoid being subjected to outer blast force or
heat when heat or blast would strike the exterior protective
shell 14. This again, as was stated earlier, is to avoid the
outer wall of the protective shell 14 of the module 10 from
collapsing causing the upper module 10 to topple. The position
as shown would also prevent any heat from entering the living
quarters during a fire or blast event.
Turning now to Figures 11 and 12, these figures show upper
views of the exterior wall 36 as it engages a corner support post
80 with a view of C beam 35 holding the wall 36 upright
throughout its length. There is also seen an interior support
post 82 which would engage the inner walls 17, 19 of the living
quarters 12, likewise having a C beam 15 supporting it. Again,
and it cannot be stressed enough, that it should be noted that
there is a void space 60 between the two walls and the C beams
15, 35 so that there is no metal contact of any type between the
walls of living quarters 12 and the walls of protective shell 14.
Turning to Figures 13 and 14, there is illustrated a side
view of the base of the module 10 wherein there is a base plate
90 that supports the outer walls of protective shell 14 through
welding of the like and the wall of the living quarters 12, where
the floor 28 is engaged. As seen in Figure 13, when the inner
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support post 82 is in place, the floor 28 of the living quarters
is welded thereupon. Again, there being a void space 60 between
the walls of the living quarters 12 and outer protective shell 14
which is filled with air and may be filled with insulation for
the reasons as discussed earlier.
In Figure16 there is illustrated again, an additional side
view of the base plate 90 upon which the supports for the walls
of living quarters 12 and protective shell 14 are engaged.
Again, there is provided L-brackets 94 which support the floor 28
of the inner living quarters unit 12 and again, there is the air
space void 60 between the wall of the protective unit 14 and the
wall of the living quarters 12. A portion of this space 60 as
will be discussed further, will be filled with insulation as was
seen in earlier figures. A discussion of the dynamics of Figure
15 will follow more in detail.
Turning now to Figures 17 and 18, these are views of the
lifting pad-eye 95, which would be at the four positions on the
roof 42 of each of the modules 10 for lifting each module 10, as
seen in overall view in Figure 9. Again, these lifting pad-eyes
95 are positioned interior of the wall of shell 14 so as to be
unaffected by any heat or blast that may engage the outer shell
14 during fire or a blast event. The body 97 of each padeye 95 is
within the protective interior of the living quarter 12, with
only the eyelet portion 99 extended outward for being engaged by
a lifting hook during movement of the module.
In Figures 19-21, there is illustrated again another view of
the continuous segment of insulation 50 which fills part of the
void space 60 between the wall of the living quarters 12 and the
outer protective 14. This insulation 50 is engaged into the
inner wall via engaging pins 55 spaced apart so that the
insulation 50 is held in place throughout the entire height of
the wall of the living quarters 12. Also, as illustrated, the
blanket of insulation 50 wraps to the exterior of the C beams 15
which are supporting the walls of living quarters 12. Again, it
should be made clear that the insulation 50 occupies some of the
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void space 60 between the wall of the living quarters 12 and
protective shell 14, but makes no contact whatsoever with the
outer wall of the protective unit 14 and no contact whatsoever
with any of the C beams 35 of the outer protective shell 14.
Figures 22 and 23 illustrate the insulation 50 it is
protecting the flow of air (Arrows 100) from the Air Vac system
supply air into and out of the living 12 for the comfort of the
occupants during use. The insulation 50 is positioned in such a
manner so that should a blast occur, the blast force or heat
would not enter through the air duct 102 of the air delivery
system as seen in the figures.
In Figure 24, there is illustrated a top view of a typical
living quarters 12 within the interior shell, interior
accommodations module 10. For example, there is a series of six
beds 110 that would house six workers; while other accommodations
modules 10 may include additional features such as meeting
quarters, desks, a kitchenette of the type that would be used for
people who will be working and spending time out on a rig or oil
production platform. Figure 25 illustrates a very important
aspect of the construction of the module 10. Although Figure 19
illustrated an upper partial view of a single corner of a typical
module 10, Figure 25 illustrates all four corners of the module
10 wherein each of the four corner posts 82 are positioned
interior to the insulation 55 which envelopes the interior
structure 14. This is very critical, since the corner posts 82
are the principal support members which would support an upper
module 10 being supported by a lower module 10. The positioning
of the insulation as seen in Figure 25 would prevent any heat
from a fire event, or force from a blast to compromise the
support integrity of the support posts 82. This would insure
that the upper supported modules 10 would not topple off of the
lower support module 10 should the modules 10 be subjected to
intense heat or force from a fire or explosion on the rig or
platform.
Reference again is now made to Figures 15A and 15B. As
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stated earlier, one of the critical aspects of this invention as
was discussed earlier, is a fact that the inner wall of the
living quarters 12 and the outer protective shell 14 make no
contact whatsoever, and are separated by the void space 60 partly
occupied by insulation 50 as seen in Figure 15A. This is vital
since in the event for example of a blast 120, as seen in Figure
15B, the force of the blast 120 which would last less than a
second would make initial contact with the wall of the outer
protective shell 14, and in doing so, would force the wall of the
shell to move inward toward the wall of the living quarters 12.
The void space 60, between the units 12 and 14 would house the
insulation 50, and would be filled with air 125 to impact buffer
some of that force. However, the air 125 would become
compressed, and would act as a force against the wall of the
living quarters 12. Therefore, when the blast occurs, there are
included vents 126 in that portion of the interior space 60 below
the floor 28 of the living quarters 12, as seen, for example, in
Figure 15. When the air void 60 is compressed by the blast, the
air 125 is allowed to vent through these vents 126, and
therefore, would not serve as additional force against the wall
of the living quarters 12. Additionally, if the blast or fire is
sufficiently hot, the heat of the blast 120 would affect the
insulation 50, and due to its ceramic nature, the 50 would tend
to melt and fill any void against the wall of the living quarters
12, and would again act as a "plastic" protective insulated shell
so that the heat of the blast again would not be able to enter
the living quarters 12. It is through this two wall construction
of these modules 10 which allows the outer protective shell 14 of
the modules 10 to take enormous amount of force from the blast or
enormous heat from the fire and be able to maintain the heat from
the blast of the fire within that space between the inner and
outer walls of the module so that the heat or the force of the
blast does not enter the interior space of the housing quarters
16 where the men are housed during such an event.
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Design Criteria and Other Data for Module
Having discussed the accommodations module 10 as illustrated
in Figures 1 through 24 above, what follows is a discussion of
other important criteria in the design and construction of the
modules 10 in the preferred embodiment.
The aluminum accommodations modules 10 of the present
invention are to be constructed of aluminum in lieu of steel.
Preferably, building sizes range from a 12' x 20" x 10'-6" (3.7 m
x 6.0 m x 3.2 m), to 16' x 70" x 10'-6" (4.9 m x 21 m x 3.2 m),
the example for this purpose in the drawings which are expected
will be a common dimension is 12' x 40' 9 5/8" x 10'-6" (3.7 m x
12.4 m x 3.2 m).
The accommodations module 10 of the present invention
underwent rigorous engineering tests to insure that is novel
features were feasible in the field. Through these tests it has
been shown that the inventors have engineered a method to
construct a USCG certified modular building for utilization on
USCG approved vessels, out of aluminum and special Firemaster
Marine Blanketing material. This method by which the walls are
constructed as to not be connected, allow the fire insulation
blanketing to be a prime barrier to potential fire hazards.
Historically, modular marine buildings exteriors have been
constructed out of steel. Due to several reasons aluminum can be
a better material to utilize for the purpose of marine
accommodations. First, Aluminum is considerably lighter, due to
the crane capacities on offshore floating platforms and boats,
the lighter the building the safer it is to lift. Also, the
lightweight on vessels serves to lighten the overall load
reducing fuel consumption considerably. Aluminum exterior
buildings can weigh half of what steel buildings do. Second and
equally important is that aluminum does not corrode (oxidize)
nearly as fast as steel in a salt laden marine environment.
Therefore, it is not necessary to install elaborate coating
systems to try to protect the exterior of the aluminum buildings
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as must be done on steel buildings making the aluminum buildings
much more maintenance friendly.
The design criteria that is novel and sets this as a unique
invention, is the method by which the building is constructed
with one interior structure separate from the exterior structure,
thus making it virtually a building inside of a building. The
preferred insulation utilized is a blanket that meets all
criteria of the USCG for exterior (A-60 fire rating) on its own.
Thus, by having the interior walls being able to stand alone,
then covered by the fire blanket insulation, this alone would
constitute a safe environment for lodgers. Along with this there
can be added an external wall (which is light weight as well)
aluminum, just to protect the fire wall blanket insulation from
the exterior environment and to provide more structural safety
for the building. Another added benefit to having the dual wall
system is that it will provide even more air space for increase
insulation benefit for greater efficiency for heating and cooling
the building.
The subject module has been designed in accordance with USCG
RP 98-01, Eighth District Interim Recommended Practice-Plan
Approval, Certification and Installation of Accommodation
Modules. It is intended that the subject building be used on
Fixed Offshore Platforms, floating structures and MODU's. (Marine
vessels of all sorts)
The Lifting and Operating calculations were based on an
Elastic Analysis as per American Aluminum Association, Allowable
Stress Design 2005. All calculations are based on welded
allowable stresses values, resulting in a higher factor of
safety.
The structural framing and cladding was designed for the
following conditions;
Lift (Dynamic)
Operating Single
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Operating Double Stacked and Single Wide
Operating Triple Stacked and Double Wide
Interior Structure, Triple Stacked
In the structural design, normal allowable stress was used in
design (no 1/3 increase in allowable). Deflection of major
members was limited to L/360 where L = member unsupported length
(in). Unity checks on members was limited to <1.00 (Utilization
Ratio).
The Primary structural framing and cladding were modeled with "
STAAD PRO" Structural Analysis software.
Preferred Materials:
Structural Fire Protection Insulation: Shall comply with USCG
NVIC 9-97, ABS Rules and 46CFR Part 164.
Insulation: 2" (5 cm) Thick "Firemaster Marine Blanket", Calcium
Magnesium - Silicate Fiber Insulation (USCG Approval Number:
164.107/1/0)
Electrical: The electrical components, wiring and bulkhead cable
transits shall comply with 46CFR Subchapter J and USCG NVIC 9-97.
Construction: Walls, floors and ceilings are constructed to have
two layers of Aluminum plate with support beams and 2" (5 cm)
Firemaster Marine Blanket sandwich between the Aluminum Plates.
Approvals:
United States Coast Guard
USCG evaluated a typical all-aluminum wall designed by
Applicants' for structural blast performance. As originally
designed, the wall system consists of an exterior layer made of a
3/16" (0.48 cm) flat plate supported by C6x2.83 stud channels at
24" (61 cm) spacing o.c. The interior layer is made of a 1/8"
(0.32 cm) flat aluminum plate supported by C3x1.42 stud channels
at 24" (61 cm) o.c. The height of the wall is 9 ft (2.7 m), edge
to edge. Applicants requested that the engineering evaluation
analyze the walls as if they were fixed at both ends; however,
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the engineering evaluation did not include the review of any
header or sill in the analysis.
The aluminum alloy - temper used is 6061-T6. Mechanical
properties for this material were obtained from an Alcoa catalog
Since blast response limits for structural aluminum have not been
published, engineering evaluation used engineering judgment in
extrapolating response ductilities from published figures for
ductile steel. The criteria compares the ratio of elongation at a
given damage level to ultimate elongation for ductile steel, and
uses the same ratios to the ultimate elongation of 6061-T6
aluminum. As for ultimate end rotations, the same response limits
as for ductile steel were assumed.
The applied design pressure is 0.25 bar (25 kPa) as
requested by LQT. Duration of the positive phase was calculated
in accordance with API RP- FB2 and found to be 608 msec. The
engineering evaluation analyzed each structural component with a
Single Degree of Freedom (SDOF) approach using proprietary
software. The deflection of the external wall causes a secondary
pressure over the internal wall, which was determined using the
engineering evaluation Shield Pressure Prediction design tool;
this pressure-time function was then used to load the internal
layer and determine its response.
The scope of this work does not include optimization of the
individual components to maximize performance and/or minimize
construction cost. Based on the engineering evaluation, it is
Applicants' opinion that the wall system could be rated for
higher loads with some modifications.
Wall System
The structural components of the walls are made of 6061-T6
aluminum. Based on information from Alcoa's catalog, mechanical
properties for this alloy - temper are as follows:
Typical minimum yield tensile strength = 35 ksi (241 MPa)
Typical minimum ultimate tensile strength= 38 ksi (262 MPa)
Typical ultimate elongation = 8% up to 1/4" (0.6 cm)
10% for 1/4" (0.6 cm) and thicker
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Typical modules of elasticity = 10,000 ksi (68,947 MPa)
All joints shall be made of 5183 aluminum welding wire.
Based on information obtained from U.S. Alloy Co.'s catalog',
ultimate tensile strength is 41 ksi (282 MPa). AS proposed by
Applicants, studs shall be welded to plates by means of fillet
welds of throat thickness not to exceed the thinner part to be
connected, with a 3" (7.6 cm) fillet every 12" (30 cm) pitch.
Loads
As requested by Applicants, the system shall be verified for
a peak applied pressure of 0.25 bar (25 kPa), equivalent to 3.63
psi (25 kPa).
Duration of positive phase was calculated in accordance with
API RP-2FB, par. C.6.3.3:
t* = 0.084 + 13,000/P
where t* = duration of positive phase in seconds
P* = nominal overpressure in Pascals (1 bar = 100,000 Pascals)
P = 0.25 bar = 25,000 Pascals
Therefore, t* = 0.604 sec, approximately 600 msec. This is
a very long event for typical blast scenarios, therefore duration
estimation is considered to be on the conservative side.
In accordance with API RP-2 FB par. C.6.3.3, the load
function is assumed to be symmetrical triangular (centrally
peaked at t*/2 = 300 msec).
Structural Response
The dynamic response of structural components under the
predicted blast loads is determined by the components as Single-
Degree-of-Freedom (SDOF) systems such as the equivalent spring-
mass system shown in Figure 2. The SDOF model for each component
is constructed using the component's mechanical properties so the
model exhibits the same displacement history as the point of
maximum deflection in the component. The displacement history of
the SDOF model is obtained with finite difference techniques
using computer programs to solve the equation of motion of the
equivalent system at discrete time steps.
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The calculated peak deflection is used to determine the
support rotation and ductility ratio, which represent the
deformation limit criteria (or damage levels) most commonly used
in blast design. The support rotation is the angle between the
original shape of a component and a straight-line segment between
the point of maximum deflection and the support. The ductility
ration expresses the maximum deflection in terms of the maximum
elastic deflection of the component. Therefore, ductility ratios
that are greater than 1 indicate that permanent deformations have
been sustained.
Aluminum Response Limits
As stated above, the most commonly accepted guidelines for
the design and analysis of blast-loaded structures, such as
ASCE' and API RP-2FP do not include response limits for
structural aluminum. Therefore, the engineering evaluation
adopted response limits based on an analogy with ductile steel.
An example is given below:
A36 steel properties:
Yield tensile strength = 36 Ksi (248 MPa)
Ultimate tensile strength = 58 ksi (400 MPa)
Ultimate elongation = 15%
Modulus of elasticity = 29,000 ksi (199,947 MPa)
Strain at yield = 36/29,000 = 0.124%
Medium response ductility limits (ASCE) = 10
Strain at medium response limit = 10 x 0.124% = 1.24%
Ratio of strain at medium response limit/ultimate elongation =
0.083
Apply same ratio to aluminum:
Ultimate elongation for average channel thickness (interpolation)
= 9.1%
Strain at medium response limit = 0.083 x 9.1% = 0.75%
Strain at yield = 35/10,000 - 0.35%
Medium response ductility limit = 0.75/0.35 = 2.15, approximately
2.
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Using similar criteria, ductility response limits for
different damage levels and aluminum components are shown in
Table 1:
Table 1. 6061-T6 Aluminum Proposed Ductility Response Limits
Component Low Medium High
Response* Response* Response*
Stud channels 1 2 4
Wall plates 1 2 4
*Component response limits are defined by ASCE1 as follows:
Low: Component has none to slight visible permanent damage.
Medium: Component has some permanent deflection. It is generally
repairable, if necessary, although replacement may be more
economical and aesthetic.
High: Component has not failed, but it has significant permanent
deflections causing it to be unrepairable.
Secondary Pressure over Internal Wall Components
As the exterior wall plate and studs react to the applied
pressure, it deflects. The deflection vs. time function is
provided as output of the SDOF model. This deflection compresses
the air between the external and the internal layers, causing a
secondary pressure over the internal wall components. This
pressure is a function of the air gap between the wall layers:
the wider the spacing, the smaller the pressure.
External Wall Plate
The 3/16" (0.48 cm) thick wall plate, spanning 24" (61 cm),
assumed to be fixed-fixed (wall plate joints are assumed to be
fully welded, and end spans should be reduced slightly
[engineering evaluation suggests 20 inches (51 cm)] to compensate
for lack of fixity at wall corners) has a predicted peak end
rotation of 2.7 degrees, peak ductility 0.41, with a maximum
deflection of 0.57 inches (1.4 cm) at 300 msec. Based on the
postulated response limits, this is a Low response (acceptable).
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External Stud Channels
The C6x3.42 stud channels spanning 9 ft (2.7 m), assumed to
be fixed-fixed as indicated by LQT, have a predicted peak end
rotation of 1.4 degrees, peak ductility 0.41, with a maximum
deflection of 1.33 inches (3.4 cm) at 300 msec. Based on the
postulated response limits, this is considered a Low response
(acceptable).
Since both plate and stud deflections peak at about 300
msec, they can be added directly to obtain the peak deflection
for secondary pressure calculations (0.57 + 1.33 = 1.90 in (4.8
cm) @ 300 msec). The response of both external components is
elastic (ductility < 1). The peak secondary pressure obtained
with our Shield Pressure Prediction Tool is 3.6 psi (25 kPa) at
300 msec.
Internal Wall Plate
The 1/8" (0.32 cm) thick wall plate, spanning 24" (61 cm),
assumed to be fixed-fixed (same as external) has a predicted peak
ductility that exceeds the proposed High response limit
(unacceptable).
Internal Stud Channels
The C3x1.42 stud channels spanning 9 ft (2.7 m), assumed to
be fixed-fixed as indicated by Applicants, have a predicted peak
end rotation and peak ductility well in excess of Medium response
limits (unacceptable).
Note that composite action on the stud channels cannot be assumed
since deformation of the plate is too high to be assumed as
collaborating in vertical flexure.
Internal Wall Plate
The 1/8" thick wall plate, spanning 12" (30 cm), assumed to
be fixed-fixed (same as external) has a predicted peak end
rotation of 1.1 degrees, and peak ductility of 0.23. This is
considered a Low response (acceptable).
Internal Stud Channels
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The C3x1.42 stud channels spanning 9 ft (2.7 m), assumed to
be fixed-fixed as indicated by Applicants, have a predicted peak
end rotation of 2.7 degrees, and peak ductility of 1.48. This is
a Medium response for a non-load bearing component (LQT has
confirmed that the roof loads shall not bear on the internal
wall). Without considering composite action, which would be
reasonable for the predicted Low plate response, this response
level is considered acceptable.
SUMMARY
The results of the engineering evaluation indicate that
response of the proposed aluminum wall system for over a 0.25 bar
applied pressure over 600 msec, as originally sketched (internal
studs spaced ever 24" (61 cm) o.c.) was determined to be
unacceptable due to excessive deformation of the internal plates
and stud channels.
By reducing the internal stud spacing to 12" (30 cm) o.c.,
the response of the system as a whole is considered acceptable.
In absence of published response values or test data for
structural aluminum, the engineering evaluation has used
engineering judgment to estimate reasonable response limits. It
should be understood that these limits are not based on any
specific blast resistant design code (such as API RP2-FP or
AS CE)
Based on the low structural demand for most of the
components, it is engineering evaluation finding that the basic
design can be fine tuned to be rated for higher design loads, or
some structural components can be resized for maximum cost
economy, keeping the current load rating. Also, testing of a
typical wall section may help to better understand the material
response and determine more accurate response limits.
The following is a list of parts and materials suitable for
use in the present invention:
PARTS LIST
Parts Number Description
10 accommodations module
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12 interior living quarters
14 exterior protective shell
15 C-beams
17, 19 side walls
20, 22 end walls
23 aluminum sheets
24 doorway
26 ceiling portion
28 floor portion
30 aluminum shell
32, 34 side walls
35 C-beams
36, 38 end walls
42 upper roof
50 insulation
52 outer surface
60 air space
64 bolting connection
66 upright anchor members
68 recesses
72 base plate
76 insulated cap
80 corner support post
82 inner support post
90 base plate
94 L-brackets
95 pad-eye
97 body portion
99 eyelet portion
100 arrows
102 air duct
110 beds
120 blast
125 air
126 vents
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All measurements disclosed herein are at standard
temperature and pressure, at sea level on Earth, unless indicated
otherwise. All materials used or intended to be used in a human
being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example
only; the scope of the present invention is to be limited only by
the following claims.
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