TREA

SELF-CONTAINED ELEVATED HOUSING KIT USING INTERMODAL SHIPPING CONTAINERS

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Information

  • Patent Application
  • 20190249413
  • Publication Number
    20190249413
  • Date Filed
    February 12, 2018
    6 years ago
  • Date Published
    August 15, 2019
    5 years ago
  • Inventors
    • Brotherton; David (St. Louis, MO, US)
  • Original Assignees
    • Excelsus LLC (St. Louis, MO, US)
Information
Abstract
A housing system comprises a plurality of intermodal shipping containers. Each of the plurality of intermodal shipping containers has a bottom, a plurality of sidewalls and a top. The plurality of intermodal shipping containers has aggregately contained inside them: a plurality of floor-forming panels connectable to form a floor that can be secured to the tops of the plurality of intermodal shipping containers; a plurality of wall-forming panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping container; and a plurality of roof-forming panels connectable to the wall to form a roof. The system preferably includes steps sized to extend from the bottom of at least one of the plurality of intermodal shipping containers to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers.
Description
CROSS REFERENCE TO RELATED APPLICATION

Not applicable.


STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.


SEQUENCE LISTING, TABLE OR COMPUTER PROGRAM ON COMPACT DISC

Not applicable.


FIELD OF INVENTION

This invention relates generally to portable housing structures and more specifically relates to self-contained housing kits.


BACKGROUND OF THE INVENTION

Approximately 40% of humans live within 60 miles of the coast globally, and that number is expected to increase with the trend of growing urban centers. Sea level rise is expected to increase between 0.65 and 1.3 feet by 2050. In addition to added flood risk due to sea level rise, climate change will also increase the risk of fluvial and flash flooding due to more intense rainfall patterns. It is widely recognized that current housing stock in flood prone areas is inadequate and climate change will continue to expand the areas of flood risk. Record rainfall in 2017 from Hurricane Harvey damaged an estimated 136,000 structures, including many that were not in FEMA designated flood zones.


Despite the known present and future risks of flooding, there are a variety of factors that have failed to deliver new flood resilient residential and commercial structures. The cost of traditional elevated housing systems can be a deterrent for their adoption in low-lying flood prone regions, especially in lower income areas.


Additionally, a variety of temporary structures are known in the prior art for use after disasters. For example, it is known for governments to use manufactured housing, tents and “sprung structures” for housing and office structures. These structures suffer from the fact that they provide for living areas typically at ground level or near ground level, which often prevents them from being used on sodden ground or grounds susceptible to flooding. In addition, structures using fabric or thin skins lack robustness and are susceptible to damage or collapse in high winds. There is thus a need in the art for a more robust, yet easily deployable housing system that can be used in flood prone regions and in regions affected by disaster.


SUMMARY OF THE INVENTION

Intermodal shipping containers are standardized containers that are transported primarily by ship, train and truck. They are used to move material globally, regionally and locally. The number of existing containers is large and makes them readily available. By report, in 2012, there were over 20 million intermodal shipping containers in the world. They also come in standardized dimensions and include standard castings at the corners for securing them down and interconnection with other containers. The typical container is a rectangular box made from corrugated steel. At one end of the container are doors allowing access to the interior of the container.


Container standards are determined by the International Organization for Standardization (ISO). For example, common container lengths include 20 feet and 40 feet. These sized containers make up some 80% of all shipping containers in existence. For the standard 20-foot container, the published ISO standards are: a) volume—33.1 cubic meters; b) maximum gross weight—30,400 kilograms; c) empty weight—2,200 kilograms; and d) net load—28,200 kilograms. Standard containers are 8 feet wide and 8.5 feet high. The containers also come in taller dimensions (known as “high cube” containers), which measure 9.5 feet high. Given its steel construct, dimensions and required capacity, the intermodal shipping container is a robust and adaptable structure. In particular, intermodal shipping containers make for readily available containers that can house and be used to transport constituent structural parts for a housing system.


The invention overcomes the deficits of prior art self-contained and disaster housing via an inventive housing system and method that utilizes intermodal shipping containers. In contrast to the prior art, the inventive housing system and method provides for robust, self-contained and readily deployable housing. The system and method provide for elevated living quarters and can be used on sodden or flood susceptible terrain. The living quarters can be made ballasted, pillared or both depending on environment.


In one embodiment the invention is directed to a housing system that comprises an intermodal shipping container. The intermodal shipping container has a bottom, a plurality of sidewalls and a top. The intermodal shipping container has contained inside it a plurality of floor-forming panels connectable to form a floor that can be secured directly or indirectly to the top of the intermodal shipping container. Also contained inside the container is a plurality of panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the top of the intermodal shipping container. The container also has inside it a plurality of panels connectable to the wall to form a roof. Structural insulated panels (“SIPs”) are preferably used to make the floor-forming panels, wall-forming panels and roof-forming panels. The container preferably includes in its contents a step kit that includes: steps, a ramp or a ladder (collectively referred to herein as “steps”) sized to extend from the bottom of the intermodal shipping container or ground level to the floor when the floor-forming panels are secured to the top of the intermodal shipping container; or materials sufficient to construct such steps.


The described embodiment housing system can include one or more joists interpositionable between and connectable to the floor and the intermodal shipping container. It may also include one or more anchors to secure the intermodal shipping container to a foundation, a footing or to one or more piers. In another version of this embodiment housing system, the container may contain one or more joists interpositionable between and connectable to the intermodal shipping container and the foundation, the footing or the one or more piers.


In a second embodiment of the inventive housing system, the housing system includes a plurality of intermodal shipping containers. Each of the plurality of intermodal shipping containers has a bottom, a plurality of sidewalls and a top. The plurality of intermodal shipping containers has aggregately contained inside them: a) a plurality of floor-forming panels connectable to form a floor that can be secured to the tops of the plurality of intermodal shipping containers; b) a plurality of panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers; and c) a plurality of panels connectable to the exterior wall to form a roof. The embodiment system preferably includes a step kit so that when finished the embodiment house has steps sized to extend from ground level or the bottom of at least one of the plurality of intermodal shipping containers to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers.


Similar to the first embodiment, the second embodiment housing system can include one or more joists interpositionable between and connectable to the floor and one or more of the plurality of intermodal shipping containers. It may also include one or more anchors to secure one or more of the plurality of intermodal shipping containers to a foundation, a footing or to one or more piers. In another version of this embodiment housing system, the plurality of containers may contain one or more joists interpositionable between and connectable to one or more of the plurality of intermodal shipping containers and the foundation, the footing or the one or more piers.


In other embodiments, the invention is directed to methods of using intermodal shipping containers to create a portable housing system.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 is a perspective cut-away view showing the inside of an intermodal container having stored therein floor-forming panels, interior and exterior wall-forming panels, roof-forming panels and tube steel supports.



FIG. 2 is a perspective view showing construction of an embodiment house at a point in which an intermodal shipping container has a plurality of floor-forming panels installed on top of the shipping container.



FIG. 3 is a perspective view of a house of a first embodiment of the present invention housing system under construction at a point in which an intermodal shipping container has a floor installed, interior and exterior walls have been installed and a roof-forming panel is connected to the walls.



FIG. 4 is a perspective view of a house of a first embodiment of the present invention housing system under construction at a point in which an intermodal shipping container has a floor installed on top, interior and exterior walls have been installed, a roof structure has been connected to the walls and stairs have been installed to access the floor of the house.



FIG. 5 is a perspective view of an alternate embodiment house built upon a single intermodal container and using a lattice of joists and cross members, such as is shown in FIGS. 8 and 9, between the floor-forming panels and the intermodal container.



FIG. 6 is a detail perspective view of an upper corner portion of an intermodal shipping container showing an exemplary manner in which floor-forming panels can be secured to the intermodal shipping container.



FIG. 7 is an alternate detail perspective view of a corner portion of an intermodal shipping container showing an exemplary manner in which floor-forming panels can be secured to the intermodal shipping container.



FIG. 8 is a perspective cut-away view showing the inside of two intermodal containers having aggregately stored therein floor-forming panels, interior and exterior wall-forming panels and roof-forming panels.



FIG. 9 is a perspective view of a house of an embodiment of the present invention housing system under construction at a point in which two spaced-apart intermodal shipping containers have a lattice of joists and cross members installed on their tops.



FIG. 10 is a perspective view of a house of an embodiment of the present invention housing system under construction at a point in which two spaced-apart intermodal shipping containers have a floor installed, interior and exterior walls have been installed and a roof structure is being connected to the walls.



FIG. 11 is a perspective view of a house of an embodiment of the present invention housing system under construction at a point in which two spaced-apart intermodal shipping containers have a floor installed, interior and exterior walls have been installed, a roof structure is being connected to the walls and stairs have been installed to access the floor of the house.



FIG. 12 is a perspective view of a house of an embodiment of the present invention housing system under construction at a point in which two spaced-apart intermodal shipping containers have a floor installed, interior and exterior walls have been installed, a roof structure has been connected to the walls and stairs have been installed to access the floor of the house. The near exterior wall has been removed so as to allow visual access into the interior of the house.



FIG. 13 is a perspective view of a house of an embodiment of the present invention housing system under construction, the house having a garage door so as to convert the space between the intermodal shipping containers into a garage.



FIG. 14 is a bottom perspective view of a house of an embodiment of the present invention housing system. The house under construction rests upon three intermodal shipping containers and has two stories, one of which stories is a top deck. The house is under construction at a point in which three spaced-apart intermodal shipping containers have a floor installed, interior and exterior walls have been installed, a roof structure has been connected to the walls and stairs have been installed to access the floor of the house.



FIG. 15 is a perspective view of a finished house of an embodiment of the present invention housing system similar to that shown in FIG. 14, the house having garage doors so as to convert the space between the intermodal shipping containers into garages.



FIGS. 16 and 17 are perspective views of a lower corner portion of an intermodal shipping container showing an exemplary manner in which the container can be secured to a foundation, a footing or a pier.



FIG. 18 is a cut-away view of an intermodal shipping container partially filled with concrete blocks to ballast the container.



FIG. 19 is a cut-away view of an intermodal shipping container showing how bracing can be added to increase the structural load bearing strength of the container.



FIG. 20 depicts exemplary ways in which a container or a vertical support beam can be connected via a container twistlock to a concrete slab foundation or to a pier.





DETAILED DESCRIPTION

Embodiments of the present invention include a self-contained housing system contained and erectable upon one intermodal shipping container and a self-contained housing system contained and erectable upon a plurality of intermodal shipping containers. In other embodiments, the invention is directed to methods of using intermodal shipping containers to create a portable housing system.


A first embodiment of a self-contained housing system contained and erectable upon one intermodal shipping container is shown in FIGS. 1-4. As shown in these figures, the invention is directed to a housing system 100 that comprises an intermodal shipping container 10. The intermodal shipping container 10 has a floor 11, a plurality of sidewalls 12 and a top 13. The intermodal shipping container 10 has contained inside it: a) a plurality of floor-forming panels 20 connectable to form a floor 30 that can be secured to the top 13 of the intermodal shipping container 10; b) a plurality of wall-forming panels 21 connectable to form an exterior wall 31 around floor 30 and that can be secured to floor 30 when the floor-forming panels 20 are secured to the top 13 of intermodal shipping container 10; and a plurality of roof-forming panels 22 connectable to the exterior wall 31 to form a roof 32. System 100 preferably includes panels 23 connectable to form one or more interior walls 34 and that can be secured to floor 30. As used herein the terms “connected” and “connectable” include, unless otherwise indicated, mechanisms, techniques or methods by which recited structure is connected to other recited structure. Both direct and indirect connection and connectability, such as but not limited to connection involving an intermediary device or structure are included within the meaning of such terms. The terms “secure” or “securing” are used as equivalents of the terms “connect” or “connecting.” As an enhancement to the basic embodiment, system 100 preferably includes step kit 35 containing steps 33 or materials necessary to build steps 33 that are sized to extend from ground level or the bottom 14 of intermodal shipping container 10 to the floor 30 when the floor-forming panels 20 are secured to the tops 13 of the plurality of intermodal shipping container 10.


The constituent elements of housing system 100 will be further explained. FIG. 1 shows a perspective cut-away view showing the inside of an intermodal shipping container 10 having stored therein floor-forming panels 20, exterior wall-forming panels 21 and roof-forming panels 22. System 100 also may include interior wall-forming panels 23. Floor-forming panels 20 are connected to top 13 of container 10 using any know mechanical attachment or bonding method. As shown in FIG. 5, support posts 43 can be used to extend the floor 30 of house 60b beyond the confines or footprint of container 10. However, as is shown in FIGS. 8 and 9 with respect to a two-container embodiment system, to increase floor or living space even further, the fundamental system 100 can includes one or more joists 40 extending beyond (outside the perimeter of) one or more of the sidewalls 12 of container 10 to receive floor-forming panels 20 and provide further support to the overhanging portion of floor 30. As a further enhancement to the system including joists 40, the embodiment system can further include cross members 42 that can extend from one joist 40 to another to create a lattice of joists 40 and cross members 42.


In the accompanying figures, the inventive system is used to construct a house, designated generally in the drawings with reference number 60 followed by a letter in order to refer to the particular embodiment house shown or under discussion. In this respect, FIG. 2 is a perspective view of a house 60a of an embodiment of the first embodiment present invention housing system 100 under construction at the beginning phases. Floor-forming panels 20 may be installed on top 13 of the container 10 or on top of floor joists 40 (depicted in FIG. 9). FIGS. 4 and 5 respectively depict exemplary houses 60a, 60b having different floor plans that vary based upon the floor plan and architecture desired by the builder. In a more preferred embodiment, floor joists 40 and cross members 42 are included in system 100 and contained within container 10.



FIGS. 3 and 4 show house 60a progressing in construction. In FIG. 3, house 60a of present invention housing system 100 is under construction at a point in which intermodal shipping container 10 has a floor 30 installed on top of it, interior wall 34 and exterior wall 31 have been installed. Roof 32 will be formed from roof-forming panels 22, a first one of which has been connected to exterior wall 31 in FIG. 3. FIG. 4 shows house 60a further completed with roof 32 completely installed. As is shown in FIGS. 3 and 4, system 100 preferably includes step kit 35 that includes steps 33 or materials necessary to construct steps 33. Steps 33 have been installed to access floor 30 of house 60a. System 100 can include posts 43 to further support floor 30 as shown in FIGS. 4 and 5.


A multitude of connecting systems may be used to connect floor-forming panels 20 to containers 10. By way of example, as shown in FIGS. 6 and 7 steel plates 44 can be affixed to floor panels then fixed via welds 45 directly to the container 10 or cross members 42 or floor joists 23. Container twistlocks 51 (shown in close detail in FIGS. 16-17) can be affixed to cross members 42 and connected to each of the container's standard corner castings 15 (shown in FIG. 6) that can receive floor forming panels 20. As shown in FIG. 7, metal “L-shaped” bracket 49 that are mechanically affixed or welded to the container and anchored to the sub-floor structural insulated panels (SIPs) or other flooring system can be used. In the depicted structure bracket 49 is secured via bolt 52 to container 10. This is merely exemplary. Any other mechanical attachment or bonding can also be used.


As shown in FIGS. 16, 17 and 20, housing system 100 may also include one or more anchors 50 to removably secure the intermodal shipping container 10 to a foundation, a footing or to one or more piers (collectively referred to in this application as “piering”). In FIGS. 16, 17 and 20, anchors 50 include twist locks 51 bolted to piering 47. This makes the container removably securable to piering 47. FIG. 16 shows intermodal shipping container 10 separate and above twist lock 51 for purposes of seeing the separate componentry that can be used to anchor intermodal shipping container to piering 47. In FIG. 17, intermodal shipping container 10 is shown secured to piering 47. FIG. 20 shows how container 10 can be securely and removably anchored to the various forms of piering 47. In another version of this embodiment housing system 100, container 10 may contain one or more low level joists interpositionable between and connectable to the intermodal shipping container and the foundation, the footing or the one or more piers.



FIGS. 8-13 shows a second embodiment 200 of the present invention housing system. As shown in these figures, housing system 200 comprises a plurality of intermodal shipping containers 10. Each of the plurality of intermodal shipping containers 10 has a floor 11, a plurality of sidewalls 12 and a top 13. The plurality of intermodal shipping containers 10 has aggregately (i.e., not necessarily individually) contained inside them: a) a plurality of floor-forming panels 20 connectable to form a floor 30 that can be secured to the tops 13 of the plurality of intermodal shipping containers 10; b) a plurality of wall-forming panels 21 connectable to form an exterior wall 31 around floor 30 and that can be secured to floor 30 when the floor-forming panels 21 are secured to the tops 13 of the plurality of intermodal shipping containers 10; a plurality of roof-forming panels 22 connectable to exterior wall 31 to form a roof 32. System 200 also preferably includes interior wall-forming panels 23 that can form an interior wall 34 connectable to floor 30. As an enhancement, system 200 preferably includes step kit 35 containing steps 33 or materials necessary to build steps 33 sized to extend from the bottom 14 of at least one of the plurality of intermodal shipping containers 10 to the floor 30 when the floor-forming panels 20 are secured to the tops 13 of the plurality of intermodal shipping containers 10.


As shown in FIGS. 9 and 10 the embodiment housing system 200 can include one or more floor joists 40 interpositionable between and connectable to the tops 13 of intermodal shipping containers 10. As with the first embodiment system 100, embodiment system 200 may include cross members 42 that can connect with joists 40 to form a structural lattice 48 on top of containers 10. Joists 40 or lattice 48 receive floor-forming panels 20 and allow for the increase in living or storage area on top of containers 10. Embodiment system 200 can include anchors 50 shown and discussed above with reference to system 100 and depicted in FIGS. 16 and 17. As with embodiment housing system 100, embodiment housing system 200 can include one or more lower level joists interpositionable between and connectable to at least one of the plurality of intermodal shipping containers 10 and piering 47.


The constituent elements of the second embodiment of the inventive housing system 200 will be further explained. Specifically, FIG. 8 shows a perspective cut-away view showing the inside of two intermodal shipping containers 10 having stored aggregately therein floor-forming panels 20, wall-forming panels 21 and roof-forming panels 22. FIG. 9 is a perspective view of a house 60b of an enhanced embodiment of the present invention housing system 200 under construction at a point in which two spaced-apart intermodal shipping containers 10 have a lattice 48 of floor joists 40 and cross members 42 installed on their tops 13. In this preferred embodiment, floor joists 40 and cross members 42 are included in system 200 and contained within containers 10. In FIG. 9 floor-forming panels 20 have not yet been installed on top of lattice 48. FIG. 10 is a perspective view of house 60c of an embodiment of the present invention housing system 200 under construction at a point in which two spaced-apart intermodal shipping containers 10 have a lattice 48 of floor joists 40 and cross members 42 installed on their tops. Floor-forming panels 20 have been installed on top of lattice 48.



FIG. 11 is an alternate perspective view of house 60c of an embodiment of the present invention housing system 200 under construction at a point in which two spaced-apart intermodal shipping containers 10 have a floor 30 installed, interior wall 34 and exterior wall 31 have been installed and a roof 32 is being connected to the exterior wall 31. As is described for embodiment system 100, in the case of embodiment system 200, a multitude of connecting systems may be used to connect floor-forming panels 20 to containers 10.



FIG. 12 is a perspective view of a nearly finished house 60c of an embodiment of the second invention housing system 200 under construction at a point in which two spaced-apart intermodal shipping containers 10 have a floor 30, interior wall 34 and exterior walls 31 installed (the near exterior wall being removed for purposes of providing a view of the interior of the house 60c). A roof 32 has been connected to the walls 31, 34 and stairs 33 have been installed to access floor 30 of house 60c. As is shown in FIGS. 11 and 12, the embodiment system 200 preferably includes a step kit 35 that includes stairs 33 or materials necessary to build such steps 33, which have been installed to access floor 30 of house 60c. FIG. 13 is a perspective view of an alternate embodiment house 60d of the present invention housing system under construction. House 60d has garage door 55 installed so as to convert the space 70 between intermodal shipping containers 10 into a garage.



FIGS. 14 and 15 show a house 60e of another embodiment system of the present invention housing system that can rest upon more than just two intermodal shipping containers 10. In the exemplary case of the housing structure shown in FIGS. 14 and 15, three intermodal shipping containers 10 are used and house 60e has two stories 65a, 65b (the top most story being a deck 66).


Additional details of the features and advantages of the inventive housing system will now be explained. The intact containers supporting a house or work structure may be used as secure storage or to house mechanical or other systems needed for the home or recovery supplies needed in the immediate area of the disaster. SIPs are preferably used to make the floor-forming panels 20, wall-forming panels 21 and roof-forming panels 22. By using SIPs for these constituent components, a rapidly deployable and easily transportable housing system is provided. As shown in FIG. 7, a SIP includes an insulating foam core 26 sandwiched between two structural facings or sheathings 27. One known facing is oriented strand board (OSB). SIPs are manufactured under factory controlled conditions and can be fabricated to fit nearly any building design. SIPs can be covered or coated with a durable finish exterior layer (a/k/a “cladding”) that can stand up to weather elements. Alternatively, a SIP can include fastener mechanisms to mechanically receive a weather-impermeable facing to create a weather proof panel for a structure.


As can be grasped from the images, by virtue of building a house or work structure on top of the intermodal shipping containers, easily-deployable housing can be placed in areas that are sodden from flooding or rain. Second, by virtue of building a house or work structure on top of the intermodal shipping containers, housing can be provided in areas in which further flooding is expected. Ground-based emergency housing solutions, particularly those relying upon fabric, films and wood structural components would not be appropriate for such locales. Moreover, by using intermodal shipping containers to elevate living or work quarters, the inventive housing system includes an easily ballastable container that can provide additional mass and support to any structure. For example, as shown in FIG. 18, once a shipping container has been located for purposes of erecting a structure it can be filed with stone, dirt, debris or dedicated weights to create housing ballast to stand up to winds or flooding. In FIG. 18, cinder blocks 66 are used as ballast inside intermodal shipping container 10. Additionally, even though intermodal shipping containers are very robust and structurally strong, by virtue of their cubic shape, they can easily receive interior bracing 68 (which bracing may be included in any of the embodiment housing systems discussed herein) as shown in FIG. 19 to add strength and rigidity to intermodal shipping container 10.


Alternatively, the corrugated steel forming the walls of the typical intermodal housing container can be cut out upon installation to create flow paths under a house. The flow would allow water to flow through the container in the event of flooding. The necessity to modify the shipping container after installation will vary based on geographic location, flood type (fluvial vs. coastal) and severity of flood risk.


The present invention is also directed to a first embodiment method of constructing a sheltering structure. The embodiment method includes providing an intermodal shipping container. The intermodal shipping container has a bottom, a plurality of sidewalls and a top and has contained inside it: a plurality of floor-forming panels connectable to form a floor that can be secured to the top of the intermodal shipping container, a plurality of wall-forming panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the intermodal shipping container, and a plurality of roof-forming panels connectable to the wall to form a roof. The method further includes: securing to the top of the intermodal shipping container the plurality of floor-forming panels to form a floor on top of the intermodal shipping container; securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create an exterior wall around the floor; and securing to the exterior wall the plurality of roof-forming panels so as to form a roof.


The present invention is also directed to a second embodiment method of constructing a sheltering structure. The embodiment method comprises providing a plurality of intermodal shipping containers. Each of the intermodal shipping containers has a bottom, a plurality of sidewalls and a top. The plurality of intermodal shipping containers has aggregately contained inside them: a plurality of floor-forming panels connectable to form a floor that can be secured to the tops of the plurality of intermodal shipping containers; a plurality of wall-forming panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers; and a plurality of roof-forming panels connectable to the wall to form a roof. The method further includes: securing to the tops of the intermodal shipping containers the plurality of floor-forming panels to form a floor on the tops of the intermodal shipping containers; securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create an exterior wall around the floor, and securing to the exterior wall the plurality of roof-forming panels so as to form a roof.


While a kit or prefabricated housing modules may conveniently be shipped within the container(s) to the construction site, there may be instances when the complete housing kit may need to be transported in separate shipments. For example, in the event of a bulk order (e.g. multiple kits being delivered to one building site), it may be more convenient and/or economical to ship building panels/modules in bulk manner to maximize the shipping volume within each container. An example would be grouping all interior wall SIPs/modules needed for multiple dwellings within a single container. Based on the specifications of a bulk order, it could be possible to ship all necessary components in fewer (or more) containers than are needed to provide the structural bases for the structures specified within a bulk order. On the other hand, there may be instances where existing unused containers are already present near the building site and only the other building components would be necessary to erect a structure. There also may be instances where additional shipping containers are used to transport materials but not utilized for structure. Accordingly, the invention includes a third method of constructing a sheltering structure. The third embodiment method includes providing: an intermodal shipping container, the intermodal shipping container having a bottom, a plurality of sidewalls and a top; a plurality of floor-forming panels connectable to form a floor that can be secured to the top of the intermodal shipping container; a plurality of wall-forming panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping container; and a plurality of roof-forming panels connectable to the wall to form a roof. The embodiment method further includes: securing to the top of the intermodal shipping container the plurality of floor-forming panels to form a floor on top of the intermodal shipping container, securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create an exterior wall around the floor, and securing to the exterior wall the plurality of roof-forming panels so as to form a roof.


A similar method of constructing a sheltering structure may be used utilizing a plurality of intermodal shipping containers. In this respect, a fourth embodiment method comprises providing: a plurality of intermodal shipping containers, each of the intermodal shipping containers having a bottom, a plurality of sidewalls and a top: a plurality of floor-forming panels connectable to form a floor that can be secured to the tops of the plurality of intermodal shipping containers; a plurality of wall-forming panels connectable to form an exterior wall around the floor and that can be secured to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers; and a plurality of roof-forming panels connectable to the wall to form a roof. The embodiment method further includes: securing to the tops of the intermodal shipping containers the plurality of floor-forming panels to form a floor on the tops of the intermodal shipping containers; securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create an exterior wall around the floor; and securing to the exterior wall the plurality of roof-forming panels so as to form a roof.


Importantly, the foregoing constituent actions of the described methods need not necessarily be done in the order described and should not be deemed strictly as serial steps. For example, the wall-forming panels may be secured to the floor formed from the floor-forming panels before securing the floor-forming panels or floor to the top of the container. The methods could include the attachment of joists, cross members or a lattice to the top of one container or extending from one container to another. The particular embodiment housing system and methods disclosed above are illustrative and may respectively include other components or steps to enhance the constructed housing structures. The housing structures shown are also merely illustrative of housing structures that can be built utilizing the inventive systems and methods. More ornate or elaborate structures may be constructed using the systems and methods disclosed herein. To better visualize the included drawings, a line may not be present at every joint where panels connect. Panel systems that can be utilized for this invention can be manufactured in a variety of sizes to meet the specific design and structural requirements of each structure.

Claims
  • 1. A housing system comprising: an intermodal shipping container, the intermodal shipping container: a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners and; c) having a bottom, a plurality of sidewalls and a top;the intermodal shipping container having contained inside it:a plurality of floor-forming panels connectable to form a floor, the floor securable to the top of the intermodal shipping container;a plurality of wall-forming panels connectable to form an exterior wall around the floor and the exterior wall securable to the floor when the floor-forming panels are secured to the top of the intermodal shipping container; anda plurality of roof-forming panels connectable to the exterior wall to form a roof.
  • 2. The housing system of claim 1 further including a step kit.
  • 3. The housing system of claim 1 further including one or more joists interpositionable between and connectable to the floor and the intermodal shipping container.
  • 4. The housing system of claim 1 further including one or more anchors to removably secure the intermodal shipping container to piering.
  • 5. A housing system comprising: a plurality of intermodal shipping containers, each of the plurality of intermodal shipping containers: a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners and; c) having a bottom, a plurality of sidewalls and a top;the plurality of intermodal shipping containers having aggregately contained inside them:a plurality of floor-forming panels connectable to form a floor, the floor securable to the tops of the plurality of intermodal shipping containers;a plurality of wall-forming panels connectable to form an exterior wall around the floor, the exterior wall securable to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers; anda plurality of roof-forming panels connectable to the exterior wall to form a roof.
  • 6. The housing system of claim 5 further including a step kit.
  • 7. The housing system of claim 7 further including one or more joists interpositionable between and connectable to the floor and one or more of the plurality of intermodal shipping containers.
  • 8. The housing system of claim 7 further including one or more anchors to removably secure one or more of the plurality of intermodal shipping containers to piering.
  • 9. A method of constructing a sheltering structure, the method comprising: providing an intermodal shipping container, the intermodal shipping container a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners; c) having a bottom, a plurality of sidewalls and a top and; d) having contained inside it: a plurality of floor-forming panels connectable to form a floor, the floor securable to the top of the container;a plurality of wall-forming panels connectable to form an exterior wall around the floor, the exterior wall securable to the floor when the floor-forming panels are secured to the top of the shipping container; anda plurality of roof-forming panels connectable to the exterior wall to form a roof;securing to the top of the intermodal shipping container the plurality of floor-forming panels to form the floor on top of the intermodal shipping container;securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create the exterior wall around the floor; andsecuring to the exterior wall the plurality of roof-forming panels so as to form the roof.
  • 10. A method of constructing a sheltering structure, the method comprising: providing a plurality of intermodal shipping containers, each of the intermodal shipping containers a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners; and c) having a bottom, a plurality of sidewalls and a top;the plurality of intermodal shipping containers having aggregately contained inside them: a plurality of floor-forming panels connectable to form a floor, the floor securable to the tops of the plurality of intermodal shipping containers;a plurality of wall-forming panels connectable to form an exterior wall around the floor, the exterior wall securable to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping containers; anda plurality of roof-forming panels connectable to the exterior wall to form a roof;securing to the tops of the intermodal shipping containers the plurality of floor-forming panels to form the floor on the tops of the intermodal shipping containers;securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create the exterior wall around the floor; andsecuring to the exterior wall the plurality of roof-forming panels so as to form the roof.
  • 11. A method of constructing a sheltering structure, the method comprising: providing: an intermodal shipping container, the intermodal shipping container a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners and; c) having a bottom, a plurality of sidewalls and a top;a plurality of floor-forming panels connectable to form a floor, the floor securable to the top of the intermodal shipping container;a plurality of wall-forming panels connectable to form an exterior wall around the floor, the exterior wall securable to the floor when the floor-forming panels are secured to the top of the intermodal shipping container; anda plurality of roof-forming panels connectable to the exterior wall to form a roof;securing to the top of the intermodal shipping container the plurality of floor-forming panels to form the floor on top of the intermodal shipping container;securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create the exterior wall around the floor; andsecuring to the exterior wall the plurality of roof-forming panels so as to form the roof.
  • 12. A method of constructing a sheltering structure, the method comprising: providing: a plurality of intermodal shipping containers, each of the intermodal shipping containers a) being a rectangular, eight-corner, closed box made of corrugated steel with doors fitted at one end; b) having castings at each corner with openings for twistlock fasteners and; c) having a bottom, a plurality of sidewalls and a top:a plurality of floor-forming panels connectable to form a floor, the floor securable to the tops of the plurality of intermodal shipping containers;a plurality of wall-forming panels connectable to form an exterior wall around the floor, the exterior wall securable to the floor when the floor-forming panels are secured to the tops of the plurality of intermodal shipping container; anda plurality of roof-forming panels connectable to the exterior wall to form a roof;securing to the tops of the intermodal shipping container the plurality of floor-forming panels to form the floor on the tops of the intermodal shipping containers;securing to the floor the plurality of wall-forming panels, the wall-forming panels being arranged on the floor so as to create the exterior wall around the floor; andsecuring to the exterior wall the plurality of roof-forming panels so as to form the roof.