AU767231B2 - Transportable building with higher roof - Google Patents

Description

7u P/00/01 1 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

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STANDARD PATENT Invention Title: Transportable building with higher roof The following statement is a full description of this invention, including the best method of performing it known to us: Freehills Carter Smith Beadle MELC600368686.4 i CD/00368649.3 TRANSPORTABLE BUILDING WITH HIGHER ROOF Field Of the Invention This invention relates generally to transportable buildings, and in one aspect is especially applicable to the provision of transportable buildings with pitched or gabled roofs.

Background of the Invention It is known to pre-construct houses or other buildings at a base yard and then to transport the buildings by road, either whole or in two or more modules, to a client's allotment. According to one approach, a house is provided in transportable half-modules with sloping roofs which are brought together on-site to °-form a house with a conventional pitched roof. A transportable house is a very satisfactory means of providing a house in a more remote or difficult location where building expenses on site may be higher than elsewhere. This approach differs from those in which buildings are erected from components or opened eg folded out from wholly collapsed assemblies.

A principal constraint in the design of transportable houses is the strict dimensional limit set by road transport authorities. One difficulty lies in providing a transportable module with a pitched roof within the dimensional limit without compromising the ceiling height of the module. Due to these height restrictions, transportable buildings have had to be designed with limited ceiling heights and/or low pitched roofs, often leaving little or no room for heating/cooling duct work within the roof space. Further, some public buildings such as schools have minimum specifications for the ceiling height of the buildings so that it is difficult to meet the external height restriction and the internal ceiling minimum within a practical configuration of transportable building module.

A further problem in providing larger public buildings such as school rooms in transportable form is the large size and mass of the beam and rafter structures required to span the wide roof space.

The structure disclosed in UK patent publication 2257170 allows for a higher pitched roof by having the upper portion of the roof trusses in a pivotably 0 0 C 82664v5 2 collapsible form. Australian patent application 10702/92 discloses a transportable house with separable lower and upper storey modules.

It is an object of the invention, at least in one or more embodiments, to provide for a transportable building in which a pitched roof of substantial inclination, or similar, can be provided without offending against a prescribed dimensional limit for road transport.

It is a further object of the invention, at least in one or more embodiments, to ameliorate the requirement to provide large and heavy span sections in transportable public buildings and the like.

Summary of the Invention In a first aspect, the invention accordingly provides a transportable building module including structure defining a floor sub-frame and at least one wall structure about a room space, the building module further including at least one roof sub-module, wherein said at least one roof sub-module is hingedly mounted to said wall structure at a first side of the building module for pivotal movement between an extended position, in which the roof sub-module defines a greater height of the building module at a second side opposite said first side, and a retracted transport position, in which retracted transport position the height of the building module is less than when said roof sub-module is in said extended 20 position, wherein said roof sub-module includes a plurality of rafters and is hingedly mounted to said wall structure by respective hinge pins coupling said rafters to said wall structure.

In its extended position, the roof sub-module is preferably disposed to define all or part of a pitched roof for the building. Advantageously, the roof sub- 25 module includes one or more gable end-wall assemblies that pivot down, outside c.a wall of the building module, with the roof sub-module as it is lowered, eg. until the roof sub-module rests on the wall. Preferably, the roof sub-module including e::e the gable end-wall(s) acts as a single rigid beam structure.

e:'.i 014282664v5 3 The building module may include internal walls having fold-down upper segments to allow the roof sub-modules to move to the transport condition.

Preferably, the invention further provides a transportable building including two or more of said building modules arranged to be linked side-by-side to form the building, each of the building modules being transported separately to a site at which the building is or to be erected.

In one embodiment, the roof sub-module may define a cathedral ceiling. In another, it may include an enclosed roof cavity. Advantageously, this roof cavity is adapted to contain or contains services, eg. wiring and plumbing. Advantageously, the roof cavity is adapted to provide a ventilation path for the building. There may be one or more ventilation fans to exhaust air to the building exterior from the roof cavity. The fans may be at one or both ends of the roof cavity.

Advantageously each of the hinge pins passes through a rafter and a wall frame stud, pole or other upright.

Advantageously, the building module further includes a verandah or porch sub-roof segment hingedly mounted to the wall structure, or more preferably to the roof sub-module, for pivotal movement between a retracted position substantially adjacent the wall structure, and an extended position projecting laterally outwardly from the roof sub-module. In the latter position, the roof sub-frame may partially 20 counterbalance the roof sub-module about the latter's hinge axis.

S"The invention still further provides, in a second aspect, a method of erecting a building including at least partially constructing the building at a first site as an assembly of building modules according to the first aspect of the invention, separating the modules and transporting them separately to a second site, S 25 locating the modules and reforming said assembly at the second site, and pivoting Ithe roof sub-modules of the building modules to their extended positions and *fastening them at those positions.

The terms "frame" and "sub-frame" herein are broadly employed and may 064282664v5 4 refer, eg, to a frame of timber or metal beams and/or other components, or to a panel structure, or to a slab frame eg a tilt slab, or to any structure serving as a supporting frame or core.

Brief Description of the Drawings The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a diagrammatic side elevation of a four-module transportable building according to a first embodiment of the first aspect of the invention, in which the left hand module, as viewed, has its roof sub-module extended and the right hand module has its roof sub-module in its retracted transport condition; Figure 2 is a view of two building modules separated and placed on respective truck trays for transport, one module having its roof sub-module already in its retracted transport condition; Figure 3 is an internal fragmentary view illustrating the use of jacks to lower the roof sub-module for transport; Figure 4 is a diagrammatic transverse cross-section showing the pair of building modules of Figure 2 erected as an assembled building; Figure 5 is an enlarged fragmentary three-dimensional schematic view of a preferred arrangement for hingedly mounting the roof sub-modules; Figure 6 depicts the complementary construction of internal walls for embodiments of the first aspect of the invention; and Figure 7 is a diagrammatic side elevation of another embodiment highlighting the single beam structure of the roof sub-module in the first aspect of the invention.

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Description of Preferred Embodiments Figures 1 illustrates, in cross-section, a segment of a partially erected single storey transportable building, for example a schoolroom, according to one embodiment of the first aspect of the invention, formed by a pair of four modules 10, 12 and a pair of similar rear modules (not visible). Each of the four main modules 10, 12 includes a floor sub-frame 13 fitted with panel flooring and a wall structure 16 about a room space 15 (Fig. and a hingedly mounted roof submodule 20. Wall structure 16 includes appropriate external cladding such as weatherboards.

The normal practice is to construct most of the house, including internal walls and fittings, at a base yard, and to then transport the house, in separate modules 10', 12', for re-erection and reassembly on a pre-prepared foundation, for example an array of stumps 90, at a client's allotment. Figure 2 shows a twomodule building after the modules 10, 12 have been separated and placed on truck trays 40 ready for transport.

With reference in part to Figure 4, each roof sub-module 20 is a selfcontained unit comprised of several spaced rafters 24, a ridge beam 55, in this case in the form of a truss, linking the upper-ends of the rafters, an internal ceiling lining 25, and external cladding 26 such as corrugated steel sheets. In the 20 particular embodiment illustrated, to provide a cathedral ceiling effect, the ceiling lining 25 is fixed atop the rafters 24, and the external roofing is secured to longitudinally extending hidden battens fixed to the rafters but disposed above lining (next page is page 7) oeeooo CD/00368649.3 7 Each of the roof sub-modules 20 is hingedly mounted to the wall structure 16 of its module utilising respective hinge pins 35 (Figs. 4 and 5) to directly pivot respective rafters of the roof sub-module to poles, wall studs, or other uprights 30 of the wall structure. This is particularly illustrated in Figure 5, where the uprights 30, which are depicted as well-spaced rectangular-section (eg. box tubular section) steel poles, project above the wall top plate 32 to receive hinge pins 35, while the rafters in turn overhang the top plate. A suitable hinge pin 35 is a steel bolt of appropriate length and strength.

The hinged mounting of the roof sub-module 20 allows it to be pivoted downwardly 10 to a retracted transport position (the left module in Figure 2) in which the rafters lie substantially horizontally and the overall height of the module is substantially reduced. In this transport position, the module 20 can be transported on a tray truck 40 with minimal height clearance. Figure 3 depicts how strategically disposed jacks such as 100 can be utilised to lower the roof sub-module under full 15 control. Alternatively, a crane might be used where appropriate.

At the erection site, the roof sub-module 20 can be pivoted upwardly, e.g. by extending jacks 100, again to its fully extended position (the right module in Figure S. 2) to form the pitched roof. With two modules brought to a complementary position opposite each other, the two complementary roof sub-modules with 20 opposite slopes can be fastened together in their raised position, either by bolting together their respective ridge beams 55, linking the upper ends of the rafters of each module, to form a solid ridge beam 45, or by means of transverse collar ties 47 (Figure Appropriate ridge capping 50 can be secured in place to complete sealing of the roof.

Where one end of the building module 10, 12 is to substantially coincide with an end of the building, the roof sub-module includes a gable end-wall 62 (Fig. comprising sheeting or planks 64 bracing a triangular ladder beam frame 63. This frame comprises an end rafter 63a, a bottom plate 50 and vertical ties 52. This gable end-wall, attached to the roof sub-module, pivots or drops down outside the end wall 17 of the building module as the roof sub-module is lowered, until ridge beam 55 rests on the end wall of the house. The end-wall thereby supports the roof sub-module, and must therefore be adequately braced and of adequate CD/00368649.3 8 strength to support the roof sub-module. The gable end-wall also adds weather protection during transport.

Internal walls 110 can be provided by the complementary construction illustrated in Figure 6: to accommodate the lowering of roof module 20, a drop-down upper section 112 of wall 110 is hingedly mounted at 114 so it can be folded down out of the way. Once in final position, the hinges 114 can be removed, and a picture rail positioned to overlay the join.

It will be seen that the roof sub-module, including especially gable end-wall(s) 62 and ridge truss beam 55, acts as a single rigid beam structure bridging walls (external or internal) on which this rigid beam rests. This single rigid beam **structure is highlighted diagrammatically in Figure 7. Moreover, the provision of S. the gable end-wall assembly 62 on the roof sub-module avoids any need to build the end-wall on site after the roof sub-module has been raised into position.

It will of course also be understood that, were it desired that the building had an enclosed roof cavity rather than a cathedral ceiling, the respective intermediate rafters could also be part of half-trusses.

Module 10' includes a hinge-up verandah or porch roof 70 (Figs. 4 and 5) of the kind disclosed in Australian patent 539799. This verandah or porch roof would ":typically have multiple spaced sub-rafters 72 directly hinged by hinge pins, eg.

bolts, 74 to the outer overhanging ends of matching roof rafters 24. This verandah or porch roof is pivotable between a retracted position against the outside face of the side wall (Figure 2, at left) and a raised position (Figures 4 and which can be maintained with respective verandah posts 76 installed on site. A benefit of this verandah or porch roof is that it effectively provides a weight counterbalance for the roof sub-module 20 about the pivot axis of hinge pins this may permit roof sub-module 20 to be raised and lowered by two or three workers without the need of a crane or jacks.

An advantage of the direct pivoting attachment of the main roof rafters to the side wall is that this arrangement strengthens the roof sub-module when lifting and creates a truss effect. Without this, it would be necessary to make the swing-up roof sub-module a lot heavier, increasing costs and creating a difficulty in lifting without a crane.

004282664v5 9 Instead of the open construction illustrated in Figure 2 and 5, roof submodule 20 may alternatively define a roof cavity, which may be used to contain services for the building such as wiring and plumbing. Ventilation fans may also be provided within the roof cavity to exhaust hot air from the roof cavity to the building exterior. In such an embodiment, ventilation openings (not shown) are provided in the ceiling to allow rising hot air from the building interior to enter the roof cavity from where it is exhausted to the exterior of the building.

It will be appreciated that the height of modules 10,12; 10', 12' with roof sub-module 20 lowered does not exceed the dimensional limits prescribed for buildings during transport, yet when constructed the building is capable of meeting the minimum ceiling height requirement of public buildings and provides an aesthetically pleasing building with a substantial pitch. The increased height of the end wall of the building provides additional advantages such as providing extra wall space for blackboards in schoolrooms, for example. It will further be appreciated that multiple cooperable sets of modules 10, 12; 10', 12' with roof sub-modules 20 may be provided and joined longitudinally to extend the length of the building. Even for a given length of modules more than one roof sub-module per building module may be necessary or preferred.

In the event that it is desired to remove the building from its erection site 20 which may arise for example with a building being used as a temporary school building the modules are able to be separated, and the roof sub-modules pivoted down again to facilitate transport to a new site.

As before, the house is first constructed at a base site to ensure each of the modules is correctly sized. The house is then dismantled and transported by truck in three modules 210, 212, 220 and re-erected at the client's allotment on a suitable foundation, for example an array of stumps 299. Main modules 210, 212 are first located on stumps 299 and secured together before roof module 220 is ":lifted by crane 294 to be received by roof sub-frames 214, 215 and fastened o thereto.

S 30 It will be appreciated that the height of main modules 210, 212 and the 064282664v5 width of main modules 210, 212 and roof module 220 is such that the modules do not exceed the dimensional limits prescribed for buildings during transport and when constructed the building meets the minimum ceiling height requirement of public buildings and provides an aesthetically pleasing building with a substantial pitch. The increased height of the end wall of the building provides additional advantages such as providing extra wall space for blackboards in schoolrooms, for example. It will further be appreciated that several cooperable sets of main modules and roof modules may be provided and joined longitudinally to extend the length of the building. Even for a given length of modules 210, 212, more than one roof module may be necessary or preferred.

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