AU2013205213A1 - Shipping of Modular Building Units - Google Patents

Abstract

- 14 Abstract An assemblage of a plurality of containers is arranged for shipping. Each container is an oversized shipping container that in substance forms a part of a building. Each container 5 is arranged into one or more groups. The containers in each group are arranged to be side by side and stacked into a plurality of levels such that such that each level takes up a combined length substantially that of the multiple of a standard shipping container width. Each group after the first group is positioned with containers end to end such that they take up a combined length evenly divisible by the length of a standard intermodal shipping 10 container. ag~

Description

- 1 SHIPPING OF MODULAR BUILDING UNITS Field of the Invention 5 The present invention relates to shipping of modular building units. Background Typically transportation of goods across sea is in a standard intermodal shipping 10 container, sometimes called a sea container. These containers can be loaded on a ship, truck or rail car for transport from one location to another. The typical dimensions of a standard intermodal shipping container are: 8 feet wide (2.44m), 20 feet (6.06m) or 40 feet long, and 8 feet 6 inches (2.59m) high. High-cube (HQ) containers are 9 feet 6 inches (2.9m) high. When shipped these containers have sufficient structural strength so 15 that they can be stacked one on top of another. However when a container or product needs to be transported across sea that does not fit within one of these standard shipping containers they must be transported individually on the top most layer of the containers being shipped, or not in containers at all. This is not 20 as efficient manner of transport. This is the case for transportable buildings and building components. For example, so-called dongas (transportable single room accommodation) are transported individually and cannot normally be stacked. The present invention seeks to provide a solution to this problem. 25 Reference to prior art documents is not an admission that they form part of the common general knowledge of a skilled person in any jurisdiction. Summary of the Present Invention 30 According to one aspect of the present invention there is provided an assemblage of a plurality of containers arranged for shipping, wherein each container is an oversized shipping container that in substance forms a part of a building, each container is arranged into one or more groups, the containers in each group are arranged to be side by side 35 such that they take up a combined length substantially that of a multiple of a standard -2 intermodal shipping container width (which is typically 2.4m (8ft)), each group further comprises two or more stacked levels of the containers side by side such that they take up a combined length substantially that of the multiple of the standard shipping container width, each group after the first group is positioned with containers end to end such that 5 the groups take up a combined length evenly divisible by the length of a standard intermodal shipping container (which is typically 6.1 m (20ft)). In an embodiment each container is of a height of a HQ shipping container. 10 In an embodiment the container is a tall container, where the tall container has a height of two other containers stacked one on another. In an embodiment a plurality of tall containers are placed side by side such they take up a combined distance of a multiple of the length of a standard intermodal shipping container, and are regarded as one container in each level of a group of containers. 15 In an embodiment each container is of a width between 2.6m and 3.6m. In an embodiment each container is of a width of about 3.4m (11'3"). In an embodiment each container is of a width of about 3.5m (11'6"). In a preferred embodiment each container is of a width of about 3.3m (11'). 20 In an embodiment each container is of a length of 6m (20'). In an embodiment each container is of a height of 2.9m (9'6"). In an embodiment each tall container is of a height of about 5.8m (19'). 25 In an embodiment each container is of a height of about 3.6m. In an embodiment each tall container is of a height of about 7.2m. In an embodiment each container is a modular unit used in construction of a building and 30 the structural elements of the container are used as structural elements of the building. In an embodiment each container in the assemblage is loaded with fixtures used in the construction of the building. In an embodiment each container is loaded to be of a similar weight to the other containers. 35 -3 In an embodiment the containers are stacked to a height within the group determined by the following constraints: a maximum height permissible for the shipment, a maximum combined weight per unit area of the shipment and a determined weight value for the group. In an embodiment the determined weight is no more than a weight at which the 5 cost of shipment is determined by weight rather than by floor area. In an embodiment the determined weight (in metric tonnes) is the floor area of a container (in square meters) x the number of containers side by side in a group x 1 metric tonne divided by 1 square meter. 10 In an embodiment the assemblage has a number of containers to evenly fit within the volume defined by the groups. In an embodiment the containers comprise a plurality of sets of container types where each set is a cluster of the modules. 15 In an embodiment the containers are stacked six high. According to one aspect of the present invention there is provided a method of loading containers for shipping, wherein each container is an oversized shipping container, said 20 method comprising placing the containers such that they are arranged into one or more groups, the containers in each group are arranged to be side by side such that they take up a combined length substantially that of a multiple of a standard intermodal shipping container width, each group further comprises two or more stacked levels of the containers side by side such that they take up a combined length substantially that of the 25 multiple of a standard shipping container width, each group after the first group is positioned with containers end to end such that the groups take up a combined length evenly divisible by the length of a standard intermodal shipping container. According to one aspect of the present invention there is provided a method of shipping 30 containers, wherein each container is an oversized shipping container, said method comprising loading the containers onto a ship according to the above method transporting the containers across sea. According to one aspect of the present invention there is provided a method of 35 transporting modular building units, wherein each building units wider than a standard -4 sized intermodal shipping container, said method comprising placing the building units such that they are arranged into one or more groups, the building units in each group are arranged to be side by side such that they take up a combined length substantially that of a multiple of a standard intermodal shipping container width, each group further 5 comprises two or more stacked levels of the containers side by side such that they take up a combined length substantially that of the multiple of a standard shipping container width, each group after the first group is positioned with building units end to end such that the groups take up a combined length evenly divisible by the length of a standard intermodal shipping container. 10 According to one aspect of the present invention there is provided an assemblage of containers arranged for shipping comprising a plurality of containers substantially arranged into a rectangular prism, wherein each container is an oversized shipping container, and the prism substantially fits to a grid sized to standard intermodal shipping 15 containers of width of 2.4m (8ft) and length of 6.1 m (20ft) in horizontal cross-section. According to one aspect of the present invention there is provided an assemblage of modular building units arranged for shipping comprising a plurality of modular building units substantially arranged into a rectangular prism, wherein each unit is wider than a 20 standard intermodal shipping container, wherein each modular building unit comprises a structural frame suitable for shipping as an intermodal shipping container, and the prism substantially fits to a grid sized to standard intermodal shipping containers in horizontal cross-section. 25 In this specification the terms "comprising" or "comprises" are used inclusively and not exclusively or exhaustively. Description of Drawings 30 In order to provide a better understanding of the present invention preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is an upper perspective view of a container to be shipped; Figure 2 is an upper perspective view of two containers to be shipped; 35 Figure 3 is an upper perspective view of three containers to be shipped; -5 Figure 4 is an upper perspective view of a tall container to be shipped; Figure 5 is an upper perspective view of two tall containers to be shipped; Figure 6A is an end view of a container to be shipped; Figure 6B is an end view of a prior art container; 5 Figure 7 is an upper perspective view of a step in assembly of a container to be shipped; Figure 8 is an upper perspective view of a step in assembly of a container to be shipped; Figure 9 is an upper perspective view of a step in assembly of a container to be shipped; Figure 10 is an upper perspective view of a step in assembly of a container to be shipped; Figure 11 is a plan view of a set of containers to be shipped; 10 Figure 12 is an upper perspective schematic view of a prior art group of containers to be shipped; Figure 13 is an upper perspective view of a pair of groups of containers to be shipped according to the present invention; Figure 14 is an upper perspective view of an assemblage of containers to be shipped 15 according to the present invention; and Figure 15 is an upper perspective view of an assemblage of containers to be shipped, including the assemblage of Figure 14. Description of Embodiments of the Invention 20 Referring to Figure 1, there is shown a modular building unit in the form of a container 10. The container 10 is a rectangular prism shaped box oriented to be longitudinally horizontal. It has a length (ix in Figure 11), a width (viii in Figure 6A) and a height (vii in Figure 6A). It also has two opposed ends (one of which is shown in Figure 6A), two 25 opposed sides a top and a bottom (not shown). Figure 2 shows two containers side by side. Figure 3 shows three containers side by side. These containers form a part of a first layer on which other containers can be stacked. Using standard intermodal shipping containers for this purpose of a building results in too 30 narrow and too low a room size for many applications, without extensive on-site modification to the container. However the inventor has discovered that if the container of an appropriate size is used to start with then this problem is overcome. When the container is of a width of about 2.6m to 3.6m and of a height of about 2.8m to 3.6m, such as a HQ container height, it is a large enough size. When the container is 3.3m in width 35 11 containers side by side take substantially the same width as 15 standard 8 feet wide -6 containers. Further, when the container is a width of 3.41 m 5 containers side bu side will take substantially the same width as 5 standard 8 feet wide containers. Compare Figures 6A and 6B, which are substantially the same scale, with the container in Figure 6B being a standard intermodal shipping container 2.44mx2.6m. 5 Figure 4 shows a tall modular building unit in the form of a tall container 20. Such a building unit may be for example a stair well. The tall container 20 is a rectangular prism box oriented to be longitudinally vertical. It has a length (half ix), a width (viii) and a height (2 x vii). The width is the same as the width of container 10. The length is half of the 10 length of the container 10. The height is twice the height of the container 10. It also has two opposed ends, two opposed sides a top and a bottom (not shown). Figure 5 shows two tall containers side by side. These tall containers form a part of two layers. In an embodiment two tall containers 20 when side by side can take the place of two containers 10 stacked one on top of another. The tall containers may contain for example a stair well 15 or elevator shaft. Figures 7 to 10 show variations to the container 10, where the container is a modular building unit, such that a plurality of modular building units may be assembled into building by connecting the building units together. The modular building units are fitted 20 out prior to shipping on site so that on site construction costs are reduced. This can be particularly advantageous when the building site is remote. As seen in these Figures the side walls and or end walls of the container can be removed. Nowadays weathering steel, such as CortenTM is used for the external container walls and this provides part of the structural strength of the container during shipping, along with frame of the container. 25 When the modular building unit forms part of an external wall the weathering steel of the container can form the external wall. Other external wall compositions may be used, such as glass reinforced polymers. In some cases the external wall can be removed (as shown in Figures 8-10). 30 Generally the modular building will be comprised of a number of different modules formed in a cluster. Figure 11 shows a set 50 of 11 containers, with two tall containers 20, six of one type 1 OB, two of a second type 1 OA and one of a third type 10C. Naturally different buildings will have different requirements so the number of units in a set, the number of different units in a set and the types of units in a set will change. Two sets 50 (where the 35 tall containers 20 are only counted once) will take up two levels of containers.

-7 Further if each container is 3.6m wide, then a width of 10 side by side containers will fit within a space usually taken by fifteen side by side standard containers. When the containers 10A, 1OB and 10C are stacked two high, the volume is substantially the same 5 as two layers of 15 standard containers, although they will be higher than the two layers of standard containers (unless they are HQ height). Figure 12 show an assemblage 80 of 12.2m (40 ft) long standard 2.4m (8ft) wide HQ containers 82. Because of the extra width of the containers 10/20, they will not fit in a one 10 for one basis in a standard intermodal shipping container grid, which has a width of 2.4m (8ft) and a length of 6.1m (20ft). In the present invention the oversized containers 10/20 are grouped into an assemblage of containers for shipping. 15 As shown in Figure 13 in the present invention the containers 10/20 are arranged into an assemblage 110 of one or more groups 100, the containers in each group are arranged to be side by side 102 such that they substantially take up a combined length of a multiple of a standard intermodal shipping container width of 2.4m (8ft). In this way the containers 20 will collectively fit within the width of the standard intermodal shipping container grid. Each group 100 further comprises two or more stacked levels of the containers in the same side by side arrangement. The assemblage 110 will be stacked to a height equal to the number of levels multiplied by the height of a container. In this case there are six levels of HQ height (17.4m). This will correspond to about the height of seven standard 25 containers (18.1m). Each extra group 100 is positioned with containers end to end 106 such that they take up a combined length divisible by the length of a standard intermodal shipping container of 6.1m (20ft). In Figure 13 there are two groups, so the total length is 12.2m (40ft). 30 Typically there are 6 groups for a combined length of 36.6m (120ft). Figure 14 shows a typical assemblage 110, which is eleven containers of width 3.3m wide or ten containers 3.6m wide, six 6.1m containers long and six containers high. In this case the length and width will be about 36m by 36m. The total number of containers in 35 this volume will be 396 or 360 (depending on whether the widths are 3.3m or 3.6m).

-8 It is desired that the volume of the assemblage be fully filled. However the number of containers to be shipped may not fully fill the volume, or there may be more containers than a given volume, but not enough to add a full group. In this case a best fit may be 5 used or a most cost effective variation of: adjusting the height, adding an extra sub-group or increasing the shipped volume for extra containers. These options can be calculated depending on the number of containers to be shipped and the cost method being used. Referring to Figure 15, there is an assemblage 110 of containers to be shipped. Next to 10 assemblage 110 are assemblages 114 and then 116, which may be assemblages of containers according to the present invention, or assemblages of standard shipping containers. In each case the distance x is the number of containers in length multiplied by the standard shipping container length of 6.1 m. Typically the lengths are in multiples of six in the case of the containers being 6.1 m, or three in the case of the containers being 15 12.2 feet long. Further in the case of, for example, assemblage 114 being standard shipping containers then they may be stacked seven high. In an embodiment the containers are stacked to a height within the group determined by the following constraints: a maximum height permissible for the shipment, a maximum 20 combined weight per unit area of the shipment and a determined weight value for the group. In an embodiment the determined weight is no more than a weight at which the cost of shipment is determined by weight rather than area. In an embodiment the determined weight (in metric tonnes) is the floor area of a container 25 (in square meters) x the number of containers side by side in a group x 1 metric tonne divided by 1 square meter. This may be for example where the tonnage of the assemblage of containers is more than the floor area of the assemblage of containers (ignoring units of measure). In some cases the cost of shipping may be determined by the greater of the tonnage of the assemblage of containers is more than the floor area of 30 the assemblage of containers (ignoring units of measure). The height is generally maximised, with limitations, to minimise the shipping cost. However the height may be limited so that the cost of shipping is determined by the lowest cost method.

-9 In an embodiment the assemblage has a number of containers to evenly fit in within the volume defined by the groups. For example there may be 66 containers in each group and if there are 6 groups, then there would be 396 containers in the assemblage. 5 In an embodiment each container in the assemblage is loaded with fixtures used in the construction of the building. For example a kitchen area may have the cabinetry, a sink and a bench installed. Insulation and an inner wall may be installed. Furthermore packaged fittings and products to be installed on site may also be included in the container for shipping. For example a bed may be packaged and shipped in a bedroom 10 container. In an embodiment each container is loaded to be of a similar weight to the other containers. Modifications may be made to the present invention with the context of that described and shown in the drawings. Such modifications are intended to form part of the invention 15 described in this specification.

Claims (24)

1. An assemblage of a plurality of containers arranged for shipping, wherein each container is an oversized shipping container that in substance forms a part of a building, 5 each container is arranged into one or more groups, the containers in each group are arranged to be side by side and stacked into a plurality of levels such that such that each level takes up a combined length substantially that of the multiple of a standard shipping container width, each group after the first group is positioned with containers end to end such that they take up a combined length evenly divisible by the length of a standard 10 intermodal shipping container.

2. An assemblage according to claim 1, wherein the combined length of a level is about an integer multiple of 2.4m. 15

3. An assemblage of according to claim 1 or 2, wherein the combined length of a level is about a multiple of 16.8m or 36m

4. An assemblage of according to any of claims 1 to 3, wherein the combined length of a level is a multiple of the width of 5 or 11 containers. 20

5. An assemblage of according to any of claims 1 to 4, wherein the container is a tall container, where the tall container has a height of two other containers stacked one on another. 25

6. An assemblage of according to claim 5, wherein a plurality of tall containers are placed side by side such they take up a combined distance of a multiple of the length of a standard intermodal shipping container, and are regarded as one container in each level of a group of containers. 30

7. An assemblage of according to any of claims 1 to 6, wherein each container is of a width between 2.6m and 3.6m.

8. An assemblage of according to any of claims 1 to 6, wherein each container is of a width of about 3.4m. 35 - 11

9. An assemblage of according to any of claims 1 to 6, wherein each container is of a width of about 3.5m.

10. An assemblage of according to any of claims 1 to 6, wherein each container is of a 5 width of about 3.3m.

11. An assemblage of according to any of claims 1 to 10, wherein each container is of a length of about 6m. 10

12. An assemblage of according to any of claims 1 to 11, wherein each container is of a height of about 2.9m.

13. An assemblage of according to any of claims 1 to 11, wherein each container is of a height of about 3.6m. 15

14. An assemblage of according to any of claims 1 to 13, wherein each container is a modular unit used in construction of a building and the structural elements of the container are used as structural elements of the building. 20

15. An assemblage of according to any of claims 1 to 14, each container in the assemblage is loaded with fixtures used in the construction of the building.

16. An assemblage of according to any of claims 1 to 15, wherein the containers are stacked to a height within the group determined by the following constraints: a maximum 25 height permissible for the shipment, a maximum combined weight per unit area of the shipment and a determined weight value for the group.

17. An assemblage of according to any of claims 1 to 16, wherein the assemblage has a number of containers to evenly fit within the volume defined by the groups. 30

18. An assemblage of according to any of claims 1 to 17, wherein the containers comprise a plurality of sets of container types where each set is a cluster of the modular building units. - 12

19. An assemblage of according to any of claims 1 to 18, wherein the containers are stacked six high.

20. A method of loading containers for shipping, wherein each container is an 5 oversized shipping container, said method comprising placing the containers such that they are arranged into one or more groups, the containers in each group are arranged to be side by side such that they take up a combined length substantially that of a multiple of a standard intermodal shipping container width, each group further comprises two or more stacked levels of the containers side by side such that they take up a combined length 10 substantially that of the multiple of a standard shipping container width, each group after the first group is positioned with containers end to end such that they take up a combined length divisible by the length of a standard intermodal shipping container.

21. A method of shipping containers, wherein each container is an oversized shipping 15 container, said method comprising loading the containers onto a ship according to the method of claim 20 and transporting the containers across sea.

22. A method of transporting modular building units, wherein each building units wider than a standard sized intermodal shipping container, said method comprising placing the 20 building units such that they are arranged into one or more groups, the building units in each group are arranged to be side by side such that they take up a combined length substantially that of a multiple of a standard intermodal shipping container width, each group further comprises two or more stacked levels of the containers side by side such that they take up a combined length substantially that of the multiple of a standard 25 shipping container width, each group after the first group is positioned with building units end to end such that they take up a combined length divisible by the length of a standard intermodal shipping container.

23. An assemblage of containers arranged for shipping comprising a plurality of 30 containers arranged into a rectangular prism, wherein each container is an oversized shipping container, and the prism substantially fits to a grid sized to standard intermodal shipping containers of width in horizontal cross-section.

24. An assemblage of modular building units arranged for shipping comprising a 35 plurality of modular building units arranged into a rectangular prism, wherein each unit is - 13 an wider than a standard intermodal shipping container, wherein each modular building unit comprises a structural frame suitable for shipping as an intermodal shipping container, and the prism substantially fits to a grid sized to standard intermodal shipping containers of width in horizontal cross-section. 5