BACKGROUND TO THE INVENTION
[0001] THIS invention relates to a method and kit for prefabricated construction. Despite
the time-saving enjoyed in the erection of prefabricated structures, as compared to
conventional building practices, this advantage is somewhat : off-set by the procedures
commonly used for secural of the components of the structure. Complicated bolting
and fixing procedures are often necessary and may be time consuming. This is especially
disadvantageous in the erection of temporary structures, such as the huts commonly
employed on major construction sites, or by geologists and surveyors who frequently
have to move their base of operations.
[0002] The invention accordingly seeks to provide a method for prefabricated construction
which is simple and rapid, and a kit for use in the method.
. SUMMARY OF THE INVENTION
[0003] A first aspect of the invention provides a method for forming a floored and walled
space including the steps of forming a floored and walled space including the steps
of positioning support blocks having grooves on their upper sides around the boundary
of the floor area of the - space, levelling the blocks, positioning floor panels to
span the floor area of the space, so that ribs depending from the floor panels engage
in the grooves in the blocks, and positioning wall panels around the boundary in engagement
with the grooves, the width of the grooves being chosen to accomodate both the ribs
and wall panels with a slide fit.
[0004] Preferably, the wall panels are initially loosely positioned and then drawn together
to form a rigid construction.
[0005] The joints between-adjacent wall panels may be sealed against the effects of inclement
weather by the insertion of a sealant between the adjacent panels. The sealant is
preferably deformable, so that when the wall panels are drawn together, the sealant
is compressed to seal the joints.
[0006] A second aspect of the invention provides a method of roofing a floored and walled
space,.including the steps of frictionally engaging at least one roof panel between
opposite wall panels of the space. This method may be used in conjunction with the
method of the first aspect of the invention, each roof panel being placed between
opposite wall panels of the space, which are then drawn together to engage the roof
panel frictionally between them.
[0007] The joints between adjacent roof panels may be sealed by the-sliding insertion of
complemental roof elements at the joints. Eaves may be provided by the sliding insertion
of eave. members at the extremities of the roof.
[0008] A third aspect of the invention provides a kit for the construction of a floored
and walled space, the kit, including a plurality of support blocks having grooves
formed on their upper sides for arrangement in a predetermined relationship around
the boundary of the floor area of the space,at least one floor panel having depending
ribs at its extremities for engagement in the grooves, a plurality of wall panels
for engagement in the grooves alongside the ribs, and means to draw the wall panels
together to hold them in position.
[0009] The grooves on the upper sides of the blocks may conveniently be formed by structural
members, such as channel sections, engaged. in the blocks.
[0010] The kit may also include a deformable sealant for insertion into the joints between
adjacent wall panels, so that when the wall panels are drawn together, the sealant
is deformed to seal the joints. A suitable sealant is silicone rubber.
[0011] For the construction of a floored. walled and roofed space, the kit may include at
least one roof panel which is frictionally engageable between opposite wall panels
of.the space. The roof panels may be supplemented by the provision of complemental
sealing elements and by the provision of complemental eave members.
[0012] For reasons of insulation, the wall panels and the roof panels may be hollow and
filled with an insulating material such as fibre-glass. To enable the construction
crew to arrange the support blocks quickly and accurately around the boundary of the
floor area of the space, the kit may also include a template engageable in the grooves.
[0013] Preferably, the floor panels of the kit are formed by securing planks in abutting
relationship to a peripheral frame. The.frame then forms the depending ribs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
Figure 1 shows support blocks being positioned with the aid of a template;
Figure 2 shows the engagement of ribs fixed to the floor panels with grooves on the
upper surfaces of a support block;
Figure 3 shows the accomodation of a rib and a wall panel in a groove on the upper
surface.of a support block;
. Figure 4 shows the connection of two adjacent wall panels, the connection being
sealed;
Figures shows the engagement of a roof panel by wall panels; and
Figure 6 shows a method of sealing joints between adjacent roof panels and of providing
an eave.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0015] As shown in Figure 1, a number of support blocks 10 are roughly positioned on the
ground. Each block is provided with a groove 12. The grooves 12 are formed by suitable
lengths of channel section, which are fixed to the blocks by lugs welded to the underside
of the webs of the channel sections and cast into the blocks.
[0016] Correct positioning of the blocks and the grooves may be achieved by the use of a
template 14, which is removed before the laying of the floor panels.
[0017] Figure 2 shows two adjacent floor panels 16 and 18 each provided with ribs 20 and
22. The floor panels are made of timber planks 24 fixed by screws 26 to the ribs 20
and 22 which are lengths of square tubular section. The floor panels are laid with
the ribs in the grooves 28. It will be appreciated that the blocks 10.in Figure 1
may be positioned solely with the use of the floor panels, instead of the template
14. Figure 3 shows a floor panel 30, which.has a rib 32, in engagement with a channel
section 34 fixed to a block 36. When all the floor panels required for the structure
have been laid, the wall panels are erected.
[0018] In Figure 3 there is illustrated.a wall panel 38 inserted into the channel section
34, in the space left.after location of the rib 32. The size of the channel.34 is
chosen so as to provide a reasonably good fit of the rib and wall panel.
[0019] Figure 4 shows the connection of adjacent.wall panels 42 and 44 by a clamping device
40. A sealant 46 may be provided against inclement weather, and the wall panels 42
may be hollow with a suitable insulating filler, such as fibre-glass 48. The action
of the clamping device draws the wall panels 42 and 44 together during connection,
thus compressing the sealant 46 to effectively close the joint.
[0020] Wall panels are connected at various desirable elevations to provide a rigid structure.
[0021] Figure 5 shows a roof panel 50 of corrugated iron. Fixed to the bottom of the corrugated
iron is an insulated ceiling 52. The.roof panel is dropped between the wall panels
54 and 56 before final fastening of the clamping devices, such as 40 in Figure 4.
As the wall panels are drawn together by the clamping devices, their top edges firmly
engage the ceiling 52, holding it against the effects of wind.
[0022] The joint.58 between adjacent roof panels 60 and 62 is sealed by sliding a narrow
section of corrugated iron 64., between the corrugated-iron of the roof panels and
the ceilings. Similarly, an eave is provided by sliding in a section of corrugated
iron 66, the eave serving to direct rain water away from the wall panels of the structure.
[0023] The wall panels may have any combination of doors and windows, preferably of such
a type that the panels have no projections. The windows may, for instance, be of a
sliding variety, and the doors may have recessed handles. Wall panels may then be
stacked far more economically when not in use.
[0024] The invention thus provides a simple and rapid method for erection of a structure,
with no involved connection procedures. The components of the structure are easily
transported and use up a minimum of space during transportation or storage. The use
of clamping devices such as 40, which is described in a co-bending patent application
allows operator's access from ! only one side of the wall panels. Due to the simplicity
of the operation the labour requirement is low.
1. . A method of forming a floored and walled space characterized by the steps of
- positioning support blocks having grooves on their upper sides around the boundary
of the floor area of the space, levelling the blocks, positioning floor panels to
span the floor area of the space, so that ribs depending from the floor panels engage
in the grooves in the blocks and positioning wall panels around the boundary in engagement
with the grooves, the width of the grooves being chosen to accommodate both the ribs
and wall panels with a slide fit.
2. A method according to claim 1, characterized by the step of drawing the wall panels
towards each other to hold them in position around the boundary.
3. A method according to claim 2, characterized by the step of sealing the joints
between adjacent wall panels by positioning a deformable sealant between adjacent
panels and drawing them towards each other to compress the sealant.
4. A method according to any one of the above claims including the step of . frictionally
engaging at least one roof panel between opposite walls of the space.
5. A kit for the construction of a floored and walled space characterized by a plurality
of support blocks having grooves formed on their upper sides for arrangement around
the boundary of the floor area of the space, at least one floor panel having depending
ribs at its extremities for engagement in the grooves alongside the ribs, and means
to draw the wall panels together to hold them in position.
6. A kit according to claim 5 in which the grooves on the upper sides of the support
blocks are formed by lengths of structural members in engagement with the blocks.
7. A kit according to either of claims.5 or 6 in which the kit includes a template
engageable in the grooves to allow the blocks to be arranged correctly in the predetermined
relationship around the boundary of the floor area of the space.
8. A kit according to any of claims 5 to 7, including at least one roof panel engageable
frictionally between opposite wall panels of the space when the oppostie wall panels
are drawn together.