Patent Grant
11697551
The present invention relates to buildings furnished from repurposed shipping containers. The present invention more particularly relates to joining multiple shipping containers.
Utilizing shipping containers in the construction of structures, it is often necessary to cut out large portions of the structural steel skin of the containers to allow creation of larger open interior spaces (beyond the width of the container). When doing so, much of the structural strength of the containers is lost, requiring the clear spans to be reinforced. Often, when cutting out the exterior steel skin, the only remaining structural material is the bottom and top rails. The bottom rail is often an approximately 6″ C-channel steel beam (there are multiple specific shapes and sizes, but for all intents and purposes they act similarly to C-channel) and the top rail is may be an approximately 2″ square steel tube (there are multiple specific shapes and sizes, but for all intents and purposes they act similarly to bolster the top rail). Neither of these are sufficient to span the types of large open spaces that are typical for bedrooms, living rooms etc. For spans in the approximately 20′ range, the bottom rail may be strong enough to support the span, but deflects more than building code would allow. And the top rail the 2″ steel tube barely can support itself in that range and is not nearly sufficient for building code.
To combat this, larger spans typically require reinforcement through the addition of large structural beams. Beams can be expensive and create cosmetic issues related to interior ceiling height. An alternate method to remedy this issue is to add webbing joining the top rail of the lower floor with the bottom rail of the top floor. Connecting them together effectively creates a 10″+steel compound beam/truss, which allows the two rails to synergistically combine their strengths create a significant amount of additional rigidity without much additional steel reinforcements.
In practice however, it is difficult to achieve the joint in the field, as the containers get in the way of the joint. With only the first floor stacked (one container high), it is easier to access the mid-span joints from over the top of the containers. When a first second-story container is stacked on to the base container, access to the intercontainer space is still accessible via the roof of the first lower container. However, the fourth container, also stacked over the first story, and all successive containers, effectively make the joint location inaccessible.
A possible solution to this problem would be to cut access holes at every location where a joint to the beams to give on-site workers the ability to access the rails, add the reinforcing steel webbing, and weld or bolt them together. This solution is time consuming and would likely require expensive on-site engineering oversight. Additionally, for factory-built buildings the holes create a lot of additional complication and reduce the effectiveness of the pre-fab concept to begin with.
Alternative solutions have attempted to solve these structural, building, access, and costs issues. Interior beams or trusses are added to support or buttress a large span. However, efficient beam/truss design requires a larger height of the beam/truss the longer the span. A typical rule of thumb for steel beam design is ½″ of height for every 1′ of span. For a 20′ span, a 10″ steel beam may be sufficient. Besides from the cost of adding large steel beams to an interior, there is the larger issue of head room to consider. Typical “High Cube” (AKA Taller) shipping containers are 9′6″ tall as measured from the exterior, and 8.9′ on the interior. When considering a built-out ceiling and some additional floor height from tile etc., the height is often less than 8.5′ tall. A 10″ beam would therefore be at ˜7.5′ mark. Typical residential construction is 9′ (lower quality is still minimum 8′) and luxury product can be 10′ or more. A low 7′ high ceiling is not preferred.
Much of the prior art is dedicated to another useful solution of reinforcing the bottom rails of the containers, reinforcement below the entire length of the span joint (potentially the entire length of the container). As the height is limited to ˜6″, it is not a very efficient use of the additional metal and will not allow one to span very far without significant amounts of material.
Another simple method for adding strength to the span is to simply put in a shim between the stories to allow the top story to rest directly on the bottom. However, if the shim is not secured in place, there is the risk of shifting and negatively impacting the structural integrity. The shims only provide compression to the compound beam created, and do not add tensile strength, and therefore are significantly weaker overall (and do not allow a long clear span).
A very common and classic solution is the installment of interior columns to reduce the loads on the rails. Beyond the negative aesthetic value, the columns occupy space and reduce the usability of the room. More creative solutions have come in the form of adding a spanning structure to the exterior of the containers. The structure can be a normal truss, exterior skeleton, I-beam etc. wherein a shipping container structure is converted into a more conventional structure, with the loss of built-in structural characteristics of the containers. This also requires additional material and labor costs, and much of the work is done on-site.
It is therefore a primary object of the present invention to allow for stacking and joining of multiple containers.
It is another object of the present invention to join multiple spanning bars from adjacent shipping containers into a single effective beam.
It is still another object of the present invention to provide access to fastening system when containers are stacked.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
The present invention is directed to a system for joining containers into a larger structure. One or more raised containers are presenting over and on top of one or more lower base containers. A unitary body fastener may be coupled to an upper longitudinal bar on a base container and a lower longitudinal bar on the raised container. A preferred embodiment has three or four containers so stacked. When four containers are used, tow base containers support two raised containers. The fastener is preferably a T-bracket with a horizontal cap plate and a vertical spine plate. The cap plate preferably mounts onto an extending surface of the lower bar of the raised containers. Preferably the extending plate is affixed to the face of the lower longitudinal bar. A spine of the bracket is preferably fixed by a horizontal, or other fastener, set through the bracket spine and affixed to one or both to the upper longitudinal bars of the base container. This can be a header bar or square bar, or other bars known in the art. Vertical bolts preferably mount the cap of the bracket onto the extending plates. The extending plate is preferably part of an angle bracket. The angle bracket is affixed, and preferably permanently affixed to the raised container. The vertical bolt through the cap plate and/or the structural bolt through the spine may be threaded. A multiple of such fastening systems with multiple brackets may be fixed along sections of the bars to create a multiple joined system.
Contemplated is also a fastening system for joining four adjacent containers, two raised containers positioned above two base containers. A first T-bracket may include a horizontal cap plate and a vertical spine plate. The cap plate preferably mates with a first extending plate fastened to a first lower longitudinal bar of at least a first raised container. At least a first portion of the horizontal cap plate is preferably positioned over the first extending plate, whereby the horizontal cap plate would be coupled to the first extending plate via a first fastener. A second fastener may couple the spine plate to both of the two base containers. This may be coupled to an upper longitudinal bar, header bar, or other position or feature as is known in the art of container structures. A vertical bolt may bind the cap plate to the raised container(s). A horizontal bolt may bind the spine plate to the base containers. A second extending plate may be fastened to a second lower longitudinal bar of a second raised container; wherein at least a second portion of the horizontal cap plate would be positioned over the second extending plate, coupling the horizontal cap plate to the second extending plate via a third fastener. A first angle bracket may be fastened to the first raised container. Preferably, the first angled bracket includes an extending plate, extending from a surface of the raised container, preferably perpendicular and/or horizontal. A second angle bracket may be fastened to the other raised container. Both the extending plates are preferably positioned horizontally whereby the cap plate may be positioned horizontally and above and adjacent, and preferably mating, the extending plates. The spine plate may be positioned vertically and set between the two base containers. Multiple fasters and brackets may be set along the length of the container to further support the joint.
The present invention also includes a method for fastening stacked adjacent containers. Preferably, the containers are positioned such that a first and second base container are set along a ground surface with longitudinal sides set adjacent one another. A third raised container may be positioned on top of at least one of the base containers. A T-bracket may be positioned so that at least a first portion of a cap plate is above and adjacent an extending plate extending horizontally from a face of a raised container. A spine plate may be positioned between (and even adjacent) the base containers or portions thereof. The spine plate may be fastened to the base containers by setting a fastener through a portion of the base containers, such as upper longitudinal bars with the spine plate set intermediate thereof. A hole may be drilled through the spine plate once in position. The cap plate may be fasted to the extending plate(s), whereby the location of vertical bars or fasteners may be noted, and holes drilled into the cap plate and the cap plate set via a second fastener.
In preparing the structure, it is contemplated that larger open areas are preferred. As such, the center or interior walls and sheathing will be removed. For instance, two 40′×8′ containers set along one another as base containers will yield an approximate 16′ width, as would the raised container level. The center walls removed, access to the lower longitudinal bar is provided. The fourth container emplaced; the two interior walls of the raised container are removed to provide an open space. The angle bracket and/or the shims, and/or the base container upper longitudinal or header bar may be accessed through a hole in the flooring between the two raised containers at the junction therebetween. The T-bracket may be emplaced from above from within the four-container structure into the floor of the raised container(s) and the fasteners applied from above. In one embodiment, the base containers may include a ceiling that is set below the upper longitudinal bar that hides the bar. A header bar may be emplaced at least partially below the ceiling, whereby a lower portion of the emplaced T-bracket spine may set down between adjacent headers in the base containers to allow a single fastener to be emplaced through a first header bar in a first base container, through the spine, and then through a second header bar in a second adjacent base container. A blocking shim may be placed between upper longitudinal bars and/or header bars before and during tightening the horizontal or other structural bolt(s).
The present invention will be described with greater specificity and clarity with reference to the following drawings, in which:
The structure 1 is preferably composed of repurposed shipping containers. As used herein, the term “repurposed shipping container”, as is generally known, refers to twenty-foot and forty-foot shipping containers, and other typical sized containers known in the art of shipping and transportation or repurposed shipping container structures. However, various sized shipping containers of varied lengths, heights, and dimensions may be useful for the present invention. Most notably, these containers include a frame structure, and many include one or more corrugated, or reinforced, sidewalls. Containers also include corrugated or otherwise strengthened roofs, ceilings, and may contain a floor and base floor surface at the bottom of the container. The frame of the containers is often composed of twelve bars spanning the edges and supporting an elongated cubic, or rectangular prism shape. Most containers are shaped with a square vertical planar cross-section shape, and an elongated longitudinal dimension spanning the majority of the length of the container. The longitudinal bars of the frames are often positioned horizontally at the bottom edges and top edges, the length of the containers. As the bottom of containers supports additional weight, many bottoms will be outfitted with a C-bar, or I-beam, as the lower longitudinal bar extending on either side of the container. In applications most suited for the present invention, upper longitudinal bars may be square bars, having a square hollow cross-section. While the upper and lower longitudinal bars are not necessarily fixed at the extreme corners or edges of the containers, the approximate location of the longitudinal bars is useful for understanding of the present invention.
As seen in
It is contemplated that at least two base containers provide the first story of structure 1. Base container 4 is set on the left side, while base container 6 is set on the right side, with base containers 4 and 6 positioned adjacent one another along the longitudinal sides so that the lower longitudinal edge of base container 4 is set along the lower longitudinal bar of base container 6, and the upper longitudinal bars are similarly set adjacent one another. Insofar as the specification is concerned, while the term adjacent may refer to two structures that are in physical contact with one another, the term adjacent may also include two items positioned near one another, either without an intervening structure, or with an intervening structure adapted to mate, contact, or couple with one or both of the two adjacent structures.
At least a first raised container 8 is set above base container 4 to provide a second story for structure 1, forming a top 14. A second raised container 9 may be set upon base container 6 to provide a rectangular or square prism structure. Structure 1 includes exterior sides 10 of the containers 4, 6, 8, and 9, as well as interior sides 12, whereby interior sides of base containers 4 and 6 are set along one another. Interior sides 12 of raised containers 8 and 9 may also be set along one another. As is known in the art, interior sides may be set adjacent or apart one another, based on the structure of the frame and support walls of containers.
Lower rail 23 may include C-bar 24 extended between corners 22, with overhang 30 and lower extension 32. C-bar 24 may include an exposed face 28. Portions of overhang 30 are removed 31, to allow for locating a fastener from above. This is set at predetermined locations in the C-bar to create a periodic or regular webbing with multiple point. For illustrations, only four locations are shown, 150, 160, 170, and 180. In other embodiments more or less fastening points may be used.
As seen in
Container 17 may include a floor surface 34, a floor support surface 35, and a bottom 36, wherein the bottom is the lowest surface of the container and the outward facing structure at the bottom of the container. Container 17 may include upper longitudinal bars 40 set along or near upper longitudinal edges 42. In a preferred embodiment of the present invention, upper longitudinal bars 40 are made of square bars. As shown in
Referring to
A T-bracket 100 is shown above floor 34. T-bracket 100 includes cap plate 102, and spine plate 106. It is preferable that T-bracket be made of a single unitary body, preferably of a strong material. Strong materials may include stiff materials, including metals, such as steel and aluminum, or other materials used in the art, or plastics, etc. Angle brackets 110 include joined plates 112, wherein joined plates are adapted to mate with C-bar face 28. In preferred embodiments, joined plates 112 are permanently fixed to C-bar faces, often via welding or integral with the C-bars, or other vertical surface in the lower longitudinal bar. Extending plates 114 serve as a top surface 115 to support lower surface 103 of cap plate 102 thereon. Raised bosses, or shafts, 118, extend upwards, preferably vertical, from extending plate 114. Raised bosses 118 preferably pass-through holes 104 in cap plate 102. Raised boss 118 is preferably threaded to mate with cap nuts 109. Raised boss 118 may be a fixed boss raising from extending plate 114, or simply a threaded bolt as is known in the art. Angle bracket 110, may also include buttress plates 116 that may be set as 45 degrees in order to buttress extending plate via tension removed from extending plate to sidewall of C-bar, or longitudinal bar. Along base containers 4 and 6, upper longitudinal bars 40 may be coupled one another via structural bolt 120 that may pass through interior and exterior plates 44C and 44D of square bar 44. Structural bolt 120 mates with structural bolt nut 124, so that structural bolt head 122 and structural bolt nut 124 fasten next to exterior walls 44D. T-bracket spine plate 106 is set between square bars 44. Square bars 44 must be separated from one another, either in placement or via shims, at least the width 101 of T-bracket spine plate 106. Spine plate 106 includes a spine hole 108 to accommodate structural bolt 120 set therethrough. As shown in
As can be seen in
The process may be iterative, wherein a fifth and sixth container may be set adjacent the fourth container structure and affixed therein via the same fastening methods to provide for a two-story container with three container width. Similarly, a third story may be affixed on top of the two-story container and affixed thereto in a similar fashion. Once installed, the T-brackets and fastening system provide for a joined four longitudinal bar beam in the structure. Interior sidewalls 12 may be removed, or retained, depending on preference of the interior structure and habitat.
The method for joining these containers is preferably as follows. Two base containers are set adjacent one another, so that the upper longitudinal bars of the two base containers are set parallel and adjacent one another, with at least a distance between the two longitudinal bars for the spine to pass therethrough and bind them. The third raised container is set above one of the two base containers. Because the angled brackets may be pre-affixed to the exterior sidewall of the lower longitudinal bars of the raised containers, and the space for the T-bracket above the angled brackets is also cleared, there is no need to have a set position for the horizontal structural bolts. When the raised container is set upon the base containers, the position of the angled brackets directs the next steps. One can access the angled brackets and drop the T-brackets over the angled brackets and fit the spine plate between the two upper longitudinal bars on the lower base container. One may then drill a hole through the upper longitudinal bars, or square bars, and through the spine plate on location, after the T-bracket is set therein. Once the spine plate is fixed to the upper longitudinal bars of the base containers, the raised boss may be fastened onto the cap plate. Alternatively, the cap holes in the cap plate may be marked and drilled into the cap plate on location to accommodate the raised bosses. If the raised bosses are fixed permanently to the extending plates, the holes in the cap plates have to be specifically positioned, otherwise, the cap plate can be set over the angle bracket extending plate and while adjacent, a bore hole may be drawn through the cap plate and the extending plate on location to allow for entry of a fastening bolt therethrough preferably in a vertical orientation. The T-bracket spine plate may be affixed to the upper longitudinal bars of the base container first with the cap plates affixed to the extending plate on the lower longitudinal bars of the raised containers next.
Once the fourth container is in place, access to the fastening system may be made through a hole in the floor at the joint between the two aligned raised containers, from above. The floor and support are cut through, removed, or not emplaced, exposing the removed overhang bar of the C-bar and the angle brackets emplaced thereon. Thereby, from inside the structure, the T-bracket fastener may be lowered into the hole between the four containers to separate the two raised containers and two base containers. The T-bracket cap may be fastened to the angle bracket and/or extending plate and mated thereto. The raised bosses/shafts from the angle bracket are preferably threaded to allow a cap nut to be emplaced therein, with the cap set between the nuts and extending plate. The bosses may then be trimmed, and the floor finished. From below in the base containers, it is imagined that the T-bracket spine sets between either the upper longitudinal bars, or extends below. The spine can be fixed through the upper longitudinal bars via the structural bolts. If a ceiling has been included in the base container(s), it is preferred that the spine extends below the ceiling. Header bars may be fixed below and parallel the upper longitudinal bars below the ceiling. If necessary, shims may be employed to ensure the lateral space or gap between the containers is wide enough to allow the thickness of the spine plate to fix therebetween. These shims may be set on either or both sides of the T-bracket spine. A blocking shim may be set under the bottom f the T-bracket spine and between the header bars (or longitudinal bars). This blocking shim provides for a lateral separation to provide and maintain tension in the structural bolt to ensure proper friction and the fastener is stable in place. The shims, also ensure that the header bar or longitudinal bars do not bend, dent, or deform under the pressures exerted by the structural bolt(s).
Referring to
As shown in
As shown in the cross-sectional view of
A ceiling 38 may be set below the longitudinal bars 44, and at least a portion of the header beams 140 extends below, or is exposed below the ceiling 38. It is preferred that the header beam is set below the longitudinal bars to ensure stiffness of the combined compound beam. Hence the remaining sheathing/walls 144 are in place over the header beam. Preferably the sheathing extends about two-to-four inches below the upper longitudinal bar 44. Above the ceiling 38, insulation 39 may be added, and the drop of the header beam allows for enough space to add insulation between the base and raised containers. As the header beam is exposed below the ceiling, the ceiling can be furnished prior to fastening the raised container above. The structural bolt can be affixed after the raised containers are set. The header beam can later be covered for aesthetic purposes.
Header beam 140 may be dropped to make a total of twelve-to-twenty-four-inch height (preferably sixteen to twenty inches) of combined beam. The structural bolt through the header beam may simply be a reinforcement, whereby a first structural bolt sis set between the longitudinal bars 44 and a second one is set below at the header beams, at each (or one or more) of the fastening system locations. The shims 142 and/or 146 provide for a gap between the containers to allow the T-bracket spine plate thickness to fit through. Shims are preferably on either side of the bracket spine. When there are dings or imperfections in the sheathing (walls) or the bars, the shims can be used to mechanically separate the structures enough to fit the bracket therebetween. A blocking shim 107 marries the header beams together and prevents the beams form deforming as the structural bolts is fastened in place. When bolting together the base containers, nut 124 is (preferably threadedly) fastened, pulling the bolt through. The blocking shim maintains the tension, stabilizes the joint, and prevents deformation of the beam upon fastening. The blocking shim is preferably left in pace to maintain the tension, wherein the header beam would be covered or hidden for aesthetic purposes. The blocking shim may be partially below the header beams, or may even be set above and on top of header beans so that a portion fits between the two adjacent header beams.
The present application includes subject matter disclosed in and claims priority to a provisional application entitled “Metal Construction Fastening System” filed Feb. 1, 2021 and assigned Ser. No. 63/144,373, describing an invention made by the present inventor, herein incorporated by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 20070000921 | Butler et al. | Jan 2007 | A1 |
| Number | Date | Country |
|---|---|---|
| WO-2017141005 | Aug 2017 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20220242661 A1 | Aug 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| 63144373 | Feb 2021 | US |
