WO1990002852A1 - Monolithic building units - Google Patents

Abstract

A variety of buildings may be formed from monolithic building units or modules (1). These units or modules (1) comprise a tubular structure formed of an inner and outer skin (5, 6), defining therebetween a space (13) which is filled with foam insulating material. The space between the inner and outer skins (5, 6) is closed by end rings (7, 8) at each end of the module (1). The module (1) has open ended tubes (9, 10, 11, 12) extending at least between end rings (7, 8), and passing through said insulating material, with tensioning strands or cables (14, 15, 16, 17) secured to at least one end ring (7, 8) and passing through said tubes (9, 10, 11, 12), whereby the composite structure of the module (1) is stressed by an amount greater than any loading stresses likely to be encountered in any given situation and to place the module (1) in uniform compression to an extent that will eliminate fatigue stresses and stress reversals.

Description

MONOLITHIC BUILDING UNITS

MONOLITHIC BUILDING UNITS

This invention relates to the building accommodation

construction field & the mass production manufacturing industry. The automated manufactured building accommodation units of production are not related to prior art

prefabrication, masonry or concrete building accommodation in that -

A. The total system consists of self-contained manufactured accommodation units which can be carried about and stacked upon each other and/or suspended from tower supporting structures to form buildings of any

configuration, breadth, depth or height that are

changeable & renewable by adding or removing or

replacing units & where the ultimate size of a building need not be pre-determined. This incremantal growth with a number of units oif different sizes & spaces coupled together in an organised section allows a series of varied but related forms & spaces. A cluster of units are tied together by access and infrastructure services & with suspended units, structure. The result is varied building forms that preserve the identity of individual units & a variety of spaces that are capable of extension & change to stand the test of time because they are changeable. Where the units are suspended there is an abundance of free space at the foot of the building. Units carry a lot less weight than

traditional building & allow maximum flexibility for steep slopes or uneven terrain, economic planning of infrastructure & building out over the water to leave the land clear for non-urban pursuits and complete freedom in configuration of layout to suit orientation, aspect, access & levels.

B. The automated manufactured building accommodation units are mass produced on a computer-guided-coordinated- assembly-production format in essence as cars are to suit varying site conditions, functional requirements & customer's choice on a scale of production unequalled elsewhere or ever before in the building industry. The manufacturing operations are carried out on a continuous production line with minimum handling where raw

materials are brought in from one end & the completed 10 units taken out from the other with minimum material & labour content, maximum efficiency & speed, precision quality & production control. All dimensions are consistent for production standardisation.

C. The accommodation unit envelops have variable cross- sections such as flat-oval & rectangular & may have tapered profiles along the length of the unit & consist of double-walled composite bonded inner & outer tubes of pre-finished sheet metal 'skins' which are formed by a continuous lockforming/rollforming machine as a non-stop operation where the 'skins' are cut to the required length & the web-core space of the composite sandwich 'capped' at the ends & composite bonded by a

non-combustible non-toxic foam of varying density or light-weight material such as foam-concrete depending on the application & compressed throughout by an amount greater than the loading stresses which would otherwise occur under loading to achieve the "momentless" state of stress condition for uniform utilisation of the strength capabilities where the whole unit acts as a beam so that the whole contributes to its structural integrity & economy & suspension free of ground space. Thus the composite structural element of the invention is of exceptional lightness & strength comprises a composite sandwich stressed by tensioning strands which pass through conduits or voids in the sandwich along the neutral axis to apply uniform compression to the whole composite structure so that it is in a rigid equilibrium condition under any pre-determined loadings likely to be imposed on it. The tensioning means may comprise a single or a multiplicity of strands as shown in the accompanying drawings which illustrate a circular composite tube configuration. It is to be understood however that the invention is not limited to this configuration & the teachings of this invention are equally applicable to structural elements of other configurations & applications. In some cases a number of structural elements may be tensioned together. In other cases the composite units may be without

tensioning members or reinforced with metal rods in lieu of strands.

D. The fully self-contained units are stackable by coupling attachments on envelop rings or end caps or coupled to suspension anchors embedded in tower support structures by invitation pin devices to allow early release of the crane & services hook-up to allow early possession & occupation. Simple locking device receptacles as with present day containers have the dual function of

lifting/locking & balance when loading, unloading & rapid fixing with quick release of the unit to allow the crane or airlifting helicopter to move onto the next unit. While the units are not primarily intended to be relocated they may be released & removed if required & replaced. The loosefit coupling of the suspended units to a support structure observes adequate tolerances & ensures positive unit isolation.

E. Uniform cross-sections of the accommodation units

allow easy interchangeability of various interior functions such as cooking, sleeping, living & working to achieve maximum functional efficiency & reduction in material & production costs. Thermally efficient airtight envelops allow constant temperature to be easily maintained & monolithic smooth skin finish without ledges an allergy free atmosphere. Furniture may be pneumatic adjustable & inflatable. Each unit has exterior exposure & natural ventilation which can respond appropriately to many conditions & requirements with optional profiles, end walls, balconies, finishes & extras, etc unit layouts, design & fitout are flexible & versatile to suit accommodation type such as apartments, offices, hospital, housing & hotels, varying lifestyles, climate conditions & regional values. The overall building may have the most varied features, form, colour & finish.

F. The invention will now be described in detail with

reference to the attached drawings - In the following description the invention will be described with reference to a unit suitable for

accommodation purposes, however, it will be appreciated that by closing at least one end of the stressed

composite structure it can be used for the storage of liquids, gases and goods and applications where strength & lightness have a premium value as in portable

compactors, overhead pedestrianways & bridges & tall masts & chimneys. In the past accommodation has been provided by prefabrication or constructing on site from the various components which are used for this purpose. This has necessitated the transportation of the various building components to the construction site and the employment of a multiplicity of skilled tradesmen from the various building trades. The supply of the

components and the activities of the various tradesmen have to be coordinated to erect the desired structure. There are usually delays in site works and these delays are a significant factor in the cost of erecting

building accommodation. In those locations where the building site is a long distance from building

resources, the delay time in completing accommodation is extremely lengthy and in certain countries there is a shortage of modern building components and tradesmen whereby satisfactory accommodation can be provided in a rapid, cost effective & efficient manner. The present invention seeks to overcome these problems by providing an accommodation unit which is manufactured as a

complete unit which is suitable for the purposes herein mentioned and in the case where the unit is used for accommodation purposes it is partitioned and provided with internal services and essential livinτ and/or working facilities requiring only to be positioned at the selected location and connected to the normal service supplies and connections eg water, power, sewerage, etc to provide a fully operable accommodation unit.

The unit and its components are manufactured and

assembled in a factory or a mobile plant ensuring that an adequate supply of materials, components and labour are available to assemble a complete self-contained unit in an efficient manner utilising modern engineering and manufacturing technology thereby ensuring substantial savings in cost and the production of a robust composite unit which can be used at virtually any location and under any climatic conditions.

The invention comprises a composite structure formed of an inner and outer skin defining therebetween a web-core space which is filled with a lightweight bonding

material eg cellular plastic or foam concrete, the space between the inner and outer skins being closed by end rings at each end of the unit, said unit having

composite walls formed of open ended tubes & in the preferred embodiments extending at least between said end rings and passing through said bonding material are tensioning strands secured to at least one end ring and passing through conduits or voids whereby the composite structure is stressed by an amount greater than the loading stresses likely to be encountered by the unit in any given situation to place said unit in uniform compression to an extent that will eliminate fatigue stresses and stress reversals.

The invention will now be described with reference to the preferred embodiments in which -

Figure 1 is a perspective view of a typical unit in accordance with the invention

Figure la is a typical sectional view on line la-la of Figure 1

Figure 2 is a typical longitudinal cross-sectional view through the unit

Figure 3 is a typical cross-sectional view of line III-

III of Figure 2

Figure 4 is a typical longitudinal sectional view illustrating one method of tensioning the unit back to a parent core structure

Figure 5 is a typical longitudinal sectional view illustrating a typical alternative method of tensioning the unit back to a parent core structure

Figure 6 is a typical floor plan layout of a single level unit

Figure 7 is a typical longitudinal sectional view of a double level unit

Figure 8 is a typical cross-sectional view of line VIII-

VIII of Figure 7

Figure 9 is a typical perspective view showing an array of units affixed to a typical space frame

Figure 10 is a typical plan view showing an array of units located around the periphery of a typical solid core service core structure

Figure 11 is a typical end view of a stack of units connected by outrigger links to form a frameless

supporting structure

The unit designated generally by the reference 1 in Figure 1 is formed of helically wound suitably profiled metal type 2. The tube thus formed does not incorporate bolting or welding but is formed with a continuous lock seam 3 which runs helically around the periphery of the tube to form a unitary structure & in addition

constitutes a reinforcement for the tube.

The walls of the tube 2 are suitably profiled as

indicated at 4 to form a self-supporting rigid

structure.

The tubes are formed by a roll former machine & are cut to the desired length.

Each unit is formed of two tubes consisting inner & outer skins, one positioned within the other to form inner & outer skins 5 and 6 spaced from each other.

End rings 7 and 8 connect the inner and out skins & in accordance with one embodiment a number of conduits 9, 10, 11 & 12 connect the respective rings & pass through the web-core space 13 between the inner and outer shells 5 and 6. The space 13 is filled with a bonding material eg varying density cellular plastic or foam concrete which bonds the skins together & the whole composite structure is stressed by an amount greater than the loading stresses likely to be encountered in any given situation to place the unit in uniform compression.

Tensioning members 14, 15, 16 & 17 are anchored to the end ring 8 & pass through one of the appropriate

conduits 9, 10, 11 & 12.

Each tensioning member is formed of a multiplicity of strands which in one embodiment where the unit is to be directly connected to a parent structure also passes through a conduit 18 embedded in the parent structure 19. The free ends of the strands in the embodiment are connected to a stressing anchorage 20 located on the parent structure & by which the strands are tensioned to support the unit in cantilevered communications with a parent structure.

In accoradnce with a modification as illustrated in Figure 5 each tensioning member is engaged with a dead end 21 to accept' the end connector 22 in which the end of the strands are wedged anchored. The end connector is secured to an anchorage arm 23 affixed to the inner end ring 7. The free ends of the strands pass through bores in the end ring 8 & the tensioned strands are locked to a tensioning member such as that described with reference to the previous embodiment however in this case the tensioning member seats against the end ring 8.

The anchorage arm in this embodiment is provided with a bore 23a & the unit is secured to a parent structure by passing the arm through a bore in the structure & locking the arm thereto by a lock pin (not shown) passing through the bore 23a. Circular formed units are provided with a floor 24 supported by the internal skin 5 & sometimes a centrally located bracing strut 25. The passages thus formed constitutes ducts which conveniently accommodate the service connections previously mentioned & storage or useable space.

The units can provide either single level or two level accommodation. Figure 6 illustrates a typical floor plan for single level accommodation. In this Figure 26 indicates a bathroom provided with partition walls 27, bath 28, toilet 29, bench & wash basins 30, 31 & door 32.

33 indicates a sleeping area having a bed 34, storage units 35, 36 & cabinet 37 seating a TV receiver 38 & light & writing facilities 39.

Adjacent the sleeping area 33 is a lounge area 40 accommodating a bench 41, chairs 42, 43, & 44 & table 45

& light fitting 46.

It will thus be seen that a unit can be sub-divided & furnished to provide compact & comfortable accommodation which is suitable for a wide variety of uses including apartments, hotel, offices and housing.

Figures 7 & 8 illustrate the unit dimensioned &

sub-divided to provide a two-level accomodation. In this case the unit is provided with a deck 47 & a

staircase 48 whereby internal access is provided to both levels.

The levels can be sub-divided & fitted out in a wide variety of ways to suit particular requirements. Figure 9 shows an array of units affixed to a space frame consisting of a number of primary vertical support pillars 49, 50 & 51 which extend throughout the height of the space frame. The pillars are connected by vertically spaced transverse annular landing or deck members 52 there being one floor member for each level in the finished structure & intermediate vertical pillars 53 extend throughout the height of the frame to form a rigid sturdy structure or space frame to which the accommodation units 1 are subsequently connected in a cantilevered manner.

As will be apparent from the drawings this form of construction provides an attractive, well ventilated structure which is suitable for high density

accommodation.

Figure 10 illustrates a structure wherein the units are affixed to a solid service core tower support structure 58 thereby providing a 'pin wheel' layout. Figure 11 illustrates an arrangement whereby the units are

interconnected by outrigger links 59

thereby providing a self-supporting multi-storey

structure. Access landings (not shown) are provided at the various levels to provide access to the units.

It will be apparent from the foregoing description that the units can be assembled in various ways & configurations to provide acceptable accommodation in even remote areas in a minimum of time. The various methods of assembly as illustrated herein are illustrative only of the manner in which the accommodation units can be used & are not to be taken as limiting the scope of the invention.

Whilst the units are shown to be of circular or oval configuration it is possible to vary the shape of the units from circular to oval or substantially square configuration or to taper the unit along its length. A typical single level unit will have the following dimentions 11 metres & 4 metres & a typical double-level unit will have the following dimensions 18 metres & 7 metres.

Claims

PATENT CLAIM

Claim 1. The total system consists of individual monolithic composite units that are fully self-contained & can be carried about & stacked on each other without a building frame or suspended to form buildings of any configuration, breath, depth or height, that are capable of extension or change but that preserve the identity of individual units.

Claim 2. The individual monolithic units of Claim 1 are mass producted on a continuous co-ordinated assembly production format in essence as motor cars are to suit varying conditions & requirements.

Claim 3. Individual units of Claim 1 consist of monolithic composite bonded shells of various shapes & sizes of lock-seamed rollformed steel or aluminium facings composite bonded adhesively & mechanically by a web-core spacing material (to keep the facings a constant distance from each other) such as a

cellular plastic or foam concrete where the type, density, thickness & finish of the materials & facings are dependent on individual conditions & requirements & the ends closed by caps or plates so that the whole unit contributes to its structural integrity, insulation & sound proofing capabilities.

Claim 4. An embodiment of Claim 3 wherein the composite

bonded core S. facings are stressed by tensioning strands in sheaths to achieve the "momentless" state of stress condition desirable for uniform

utilization of the strength capabilities where the whole construction acts as a beam.

Claim 5. An embodiment of Claim 3 wherein the composite bonded core & facings are reinforced by steel rods or bars to achieve a rigid structure under loaded conditions.

Claim 6. Individual units of Claim 1 may be coupled together or suspended off support structures by strands of Claim 4.

Claim 7. Individual units of Claim 1 may be coupled together vertically by outrigger links thereby providing a self-supporting building without a support structure.