GB2322389A - Construction of Stables - Google Patents

Abstract

A composite panel (8) for a stable building comprises an outer wall (24), an inner wall (26) and an insulating core (28) sandwiched between the outer and inner walls, and a peripheral spacer element (36) located between the peripheral edges of the outer and inner walls. The support structure supporting posts (3,4) and rafters (6). The inner wall may be of plywood, and may have a lower lining (30) of rubber, and an upper lining (32) of steel. An insulated sliding door (9) may be provided.

Description

STABLE SYSTEM The present invention relates to a stable system and in particular to a barn stable system of modular design.

The advantages of the conventional in-barn stable are well known - horses and grooms can work under cover at all times. However, conventional in-barn stables have several disadvantages. Brick built barns are expensive and take a long time to build. They tend to be poorly ventilated and can be dusty. If there is an illness with one horse, isolation can be a problem. On the other hand, large timber stables tend to be hot in summer and cold in winter. Timber stables are easy to make and consequently often result in inferior building. Timber stables also have an increased risk of fire breaking out in a single, self-contained building. Furthermore, for both brick and timber stables temperature regulation, which is becoming increasingly important for performance horses, is difficult.

The present invention has been made from a consideration of the disadvantages with known in-barn stables and in order to provide an improved stable system which overcomes one or more of these problems. Preferred objects of the invention are to provide a properly insulated, easily erected stable building which is extremely strong, hygienic, easy to manage and virtually maintenance free, creating a safe and regulatable environment for the horse.

The modular design of the invention means that the entire barn can be easily shipped anywhere in the world and quickly installed. The system is flexible and insulated which means that living accommodation can be included if required.

According to a first aspect of the invention there is provided a composite panel for a stable building comprising an outer wall, an inner wall and an insulating core sandwiched between the outer and inner walls, and a peripheral spacer element located between the peripheral edges of the outer and inner walls. The composite panel may comprise a wall panel or a roof panel.

Preferably, the outer wall comprises a rigid, fire resistant board such as cement board. Preferably, the inner wall comprises plywood or plasterboard. Preferably, the spacer element comprises timber.

Preferably, the insulating core comprises a foam such as polyurethane foam or other expanding foam. Preferably, a rubber lining, or high impact resistant material, is provided on the lower region of the inner wall.

Preferably, a steel, metal or other chew resistant lining is provided on the upper region of the inner wall.

Preferably, the metal lining is bent to cover an upper edge of the rubber lining.

Preferably, the peripheral spacer element comprises a groove therealong. Preferably, an elongate tongue element is provided in such groove along one or more peripheral edges of the panel. Preferably, the elongate tongue elements and the grooves are adapted to facilitate interconnection of a plurality of wall panels of the invention.

According to a second aspect of the invention, there is provided a method of constructing a composite wall panel for a stable building comprising locating peripheral spacer elements between the peripheral edges of an inner and outer wall, injecting an insulating material into or placing a rigid insulating material into the space between the inner and outer walls and allowing the insulant material to set to form a core, which is bonded to the outer and inner layer.

Preferably, the insulating material comprises a foam such as polyurethane foam or expanding foam.

The method may include applying linings and tongues and grooves as described above to the panel formed. The panel elements are preferably as described above.

The invention includes a panel formed according to a method of the invention.

According to a third aspect of the invention, there is provided a support structure for a stable building comprising a frame for supporting one or more rafters wherein the frame comprises one or more first supporting posts each adapted to be secured adjacent one end of a corresponding rafter and one or more intermediate supporting posts each adapted to be secured to an intermediate region of a corresponding rafter.

Preferably, the layout of the supporting posts is such that the posts support the internal stable walls, for example by means of suitable lugs, and extended regions of the intermediate posts, that is extending above the height of the internal stable walls, support the rafters.

Preferably, two sets of intermediate posts are provided, one set extending upwardly further than the other so that each rafter is supported at two intermediate positions.

Preferably, the intermediate posts comprise plates at the upper ends thereof, the plates being adapted to be secured to the rafters.

Preferably, the first posts comprise fin or laterally extending plates welded or otherwise secured thereto for securing the posts to the rafters.

Preferably, the frame comprises metal such as steel.

According to a fourth aspect of the invention, there is provided a modular stable system comprising a support structure of the invention and a plurality of composite panels of the invention adapted to be secured to the support structure to form a stable building.

The invention further provides a stable formed using a modular stable system of the invention.

The invention will now be described further by way of example only and with reference to the accompanying drawings in which: Fig. 1 is a front sectional view of an embodiment of stable of the invention; Fig. 2 is a plan view showing the internal lay-out of an embodiment of a stable of the invention; Fig. 3 is a detailed view of a mid-rafter support; Fig. 4 is a detailed view of an end-rafter (eaves) support; Fig. 5 is a detailed back view of the end-rafter support of Figure 4; Fig. 6 is a front view of a rafter component; Fig. 7 is a sectional view through a wall panel; Fig. 8 is a front view of one form of wall panel; and Fig. 9 is a side sectional view of the stable showing the wire gable end bracing which is fitted at both ends of the building.

Referring to Fig. 1, a stable of the invention comprises a frame structure having a plurality of posts 2, 3, 4 supporting rafters 6. The posts 2, 3, 4 are extended columns which extend beyond the upper level of the internal stables. The outer ends of the rafters 6 are supported on posts 2 as shown in more detail in Fig. 4 and the rafters 6 are supported in mid-positions by posts 3 and 4 as shown in more detail in Fig. 3.

The walls of the building are clad with wall panels 8 which are described below with reference to Figures 7 and 8. The building is provided with insulated sliding doors 9. The building can be varied in length by discrete increments, typically in 1200 mm or 600 mm increments.

Typically the posts are of the order of 70 x 70 x 3 mm galvanised square section posts and have anchor plates (not shown) for connection to the floor of the stable, lugs (not shown) for connection to the wall panels and a top plate 10 for connection to the rafters 6 as shown in Fig. 3. Any suitable fixing means such as bolts or machine screws 12 may be used to secure the top plate 10 to the rafter 6.

Referring to Figures 4 and 5, the end posts 2 are secured to the ends of rafters 6 by a fin plate structure.

The fin plate 14 is welded to the post 2 and secured by suitable means such as bolts or machine screws, to the rafter 6. Typically the fin plate 14 may be about 10 mm thick. By using a fin plate welded to the support post, the connection to the rafter can be simple and small.

This method can be used because of the way the rafter is supported at mid-positions 3 and 4. Sideways bracing is achieved by using the grill sections 18 or wall panels 8 is held in place by the ladder truss 20 at the eaves which enables the outer walls to be strengthened and provides ventilation. Purlins 22, typically of metal such as steel can be used as pathways for wiring, water supply or the like. Suitable covers may be fitted to prevent dust build-up. Larger purlin sizes or gauges can be used where larger bay spacings are required.

Referring to Fig. 6, the rafter component 6 is typically set at about 20C to the horizontal and is drilled at locations 16 for connection to the support posts 2, 3, 4 and at 17 for the apex connection. The rafter component can be small because of the way it is supported by the posts. Typically less than about 6 m in length, it can containerised for ease of shipment. The structural design of the rafter allows for a snow loading of 60 kg (0.6Kn) per m2 and the building is designed to withstand a wind speed of 50 m/s. Correspondingly the building will withstand an uplift of 5 Kn per l/m of building.

Referring to Fig. 2, the layout for a six horse barn is shown and the relationship between the internal structure 18, typically of steel, and the exterior walls 8 can be seen. The position of the posts 2, 3, 4 may be chosen for example such that the grill section 18 is standard at 2320 mm.

As seen from Figure 9, four sets of support post structures similar to that shown in Figure 1 are provided along the length of the stable building and the purl ins 22 span the length of the building.

Referring to Figures 7, the wall panel 8 construction comprises an outer wall 24 of high impact, fire resistant board such as cement board, typically fully compressed and 6 mm and an inner wall 26 of plywood or other lining as required, typically about 12 mm thick. The outer wall may have a masonry paint finish. The space between the outer and inner wall is filled with insulant that is or will become rigid, such as polyurethane foam 28 which provides strength insulation and cohesion to the panels. A high impact resistant lining, for example about 18 mm rubber lining is applied to the lower region thereof and bent over the rubber lining at 34 is a metal flashing.

An inner spacer 36 is provided around the periphery of the panel and has a formed groove 38 adapted to receive a loose strengthening tongue 40. This allows interconnection between adjacent panels. A ground anchor channel 42 is provided at the edge of the panel adjacent the ground. The tongue and groove connection method stiffens and weathers the joint. The inner linings of rubber 30 and steel 32 prevent the horse from causing damage by kicking or chewing, respectively. The exterior cement board provides a high impact surface which is also non-combustible unlike conventional timber cladding options.

In constructing the panel, the inner and outer wall are laminated to the inner spacer and the inner core is then fitted with insulant which bonds the inner and outer layers of the wall together. The insulation core can be injected for example as an expanding foam which is allowed to set to bond the inner and outer layers of the wall together. Alternatively the insulation core may comprise a sheet of insulating foam, which may be rigid or semirigid, and the core may be located between the walls and bonded thereto by suitable adhesive means such as glue.

The composite panels may be cured in a press.

The use of plywood for the inner wall provides a rigid strength to the building and acts as a carrier for the kicking and chewing layers of rubber and galvanised steel, or other suitable materials.

The composite wall construction eliminates unwanted drafts and cold spots and allows the environment within the building to be controlled. Typically an air filter will be provided to remove dust and bacteria and to regulate temperature and air quality. A similar panel construction may be used to clad the roof.

The inner wall of panels used in staff accommodation sections of the building may comprise plasterboard.

Referring to Fig. 8, the exterior surface of the panel 8 may be decorated as desired. As shown, a stained plywood arch detail 44 and stained timber cover laths 46 surround a painted wall panel exterior 58 and a painted dado exterior 50. Decorative coated metal sheeting can also be used externally.

The building may be designed to have any suitable dimensions. Preferably, the length is a discrete number of multiples of a given length, for example multiples of 1200mm.

The roof and wall panels are both highly insulated and typically provide an insulation value equivalent to 1500 mm of fibre class insulation. The composite panels are typically of the order of 65 mm thick. Where higher or lower levels of insulation are required wall and roof thickness can be increased or decreased.

It will be appreciated that the present invention is not intended to be restricted to the details of the above embodiment which is described by way of example only.

Claims (25)

1. A composite panel for a stable building comprising an outer wall, an inner wall and an insulating core sandwiched between the outer and inner walls, and a peripheral spacer element located between the peripheral edges of the outer and inner walls.

2. A composite panel according to claim 1, wherein the outer wall comprises a rigid, fire resistant board.

3. A composite panel according to any preceding claim, wherein the inner wall comprises plywood or plasterboard.

4. A composite panel according to any preceding claim, wherein the spacer element comprises timber.

5. A composite panel according to any preceding claim, wherein the insulating core comprises a foam.

6. A composite panel according to any preceding claim, wherein a high impact resistant material, is provided on the lower region of the inner wall.

7. A composite panel according to any preceding claim, wherein a chew resistant lining is provided on the upper region of the inner wall.

8. A composite panel according to claim 7 when dependent on claim 6, wherein the chew resistant lining is bent to cover an upper edge of the impact resistant material.

9. A composite panel according to any preceding claim, wherein the peripheral spacer element comprises a groove therealong.

10. A composite panel according to claim 9, wherein an elongate tongue element is provided in such groove along one or more peripheral edges of the panel.

11. A composite panel according to claim 10, wherein the elongate tongue elements and the grooves are adapted to facilitate interconnection of a plurality of said panels.

12. A method of constructing a composite wall panel for a stable building comprising locating peripheral spacer elements between the peripheral edges of an inner and outer wall, injecting an insulating material into or placing a rigid insulating material into the space between the inner and outer walls and allowing the insulant material to set to form a core, which is bonded to the outer and inner layer.

13. A method according to claim 12, wherein the insulating material comprises a foam.

14. A support structure for a stable building comprising a frame for supporting one or more rafters wherein the frame comprises one or more first supporting posts each adapted to be secured adjacent one end of a corresponding rafter and one or more intermediate supporting posts each adapted to be secured to an intermediate region of a corresponding rafter.

15. A support structure according to claim 14, wherein the layout of the supporting posts is such that the posts support the internal stable walls and extended regions of the intermediate posts, that is extending above the height of the internal stable walls, support the rafters.

16. A support structure according to any preceding claim, wherein two sets of intermediate posts are provided, one set extending upwardly further than the other so that each rafter is supported at two intermediate positions.

17. A support structure according to any preceding claim, wherein the intermediate posts comprise plates at the upper ends thereof, the plates being adapted to be secured to the rafters.

18. A support structure according to any preceding claim, wherein the first posts comprise fin or laterally extending plates secured thereto for securing the posts to the rafters.

19. A support structure according to any preceding claim, wherein the frame comprises metal.

20. A modular stable system comprising a support structure as claimed in any preceding claim, and a plurality of composite panels as claimed in any preceding claim adapted to be secured to the support structure to form a stable building.

21. A stable formed using a modular stable system according to claim 20.

22. A composite panel substantially as hereinbefore described with reference to the accompanying drawings.

23. A method substantially as hereinbefore described with reference to the accompanying drawings.

24. A support structure substantially as hereinbefore described with reference to the accompanying drawings.

25. A stable substantially as hereinbefore described with reference to the accompanying drawings.