Methods of Constructing Buildings Using Steel Containers

Abstract

A building is provided, comprising at least two shipping containers, said containers comprising a top wall, a bottom wall, and two opposed side walls, said containers being mounted to a foundation in a spaced-apart, parallel manner, wherein portions of the adjacent inner side walls of said containers are removed, and further wherein a roof is attached to the top walls of said containers.

Description

FIELD OF THE INVENTION

The present invention relates generally to methods of constructing buildings for commercial and residential use, and in a particular though non-limiting embodiment, to a method of constructing buildings using a combination of standard construction materials and steel containers.

BACKGROUND OF THE INVENTION

There are many known methods in the art for constructing a building. Typically a building is constructed on-site, requiring many hours of skilled labor and using common construction supplies, such as brick, mortar, and lumber. Such supplies are often very costly. Furthermore, typical construction may not be strong or durable enough in certain areas of the country more prone to earthquakes, hurricanes, and other serious weather.

Recently, more cost-effective methods of construction have been proposed. One such method is to fabricate a building of steel in a factory and then move the building to the desired site. This method has proven to be faster and less expensive than traditional construction methods.

However, the metal used in such construction is very heavy and expensive to transport. Also, when using a traditional pre-fabricated metal building, there is a subsequent inability to expand the interior user space. Furthermore, steel buildings are frequently not as aesthetically pleasing, and do not have the look or feel of a traditionally constructed building. There is, therefore, a long-standing yet unmet need for methods of constructing homes in a stronger, economical and time-efficient manner, while still pleasing prospective owners aesthetically.

Turning for a moment to a seemingly unrelated issue, as more products are shipped to the U.S. from overseas, particularly Asia, ever greater numbers of metal shipping containers have begun stacking up in the major shipping ports. Consequently, it is oftentimes less expensive to buy new shipping containers in Asia than it is to ship the old containers back to the U.S. Moreover, the useful life of a standard shipping container is only about five (5) years. After that time, the containers just sit empty in abandoned shipyards.

A standard shipping container range from 19 feet to 55 feet long, 7 feet to 9 feet wide and 8 feet to 10 feet high. The containers are typically made of stronger steel than standard steel, known as Cor-ten steel, which does not rust or corrode. Furthermore, the steel is mold-resistant. The floor of a standard shipping container is made of hardwood and is constructed to withstand several tons of internal weight. The containers are built to withstand typhoons, tornadoes, hurricanes, and earthquakes.

Due to their durability, adaptability, light weight, low cost, and ease of stackability, new ideas for reusing the containers are currently being sought.

The shipping containers have been used in the past as storage units, temporary secure spaces at construction sites, and make-shift shelters. Furthermore, the containers have been used as small offices, workshops, or even employee quarters.

Therefore, there is also a long-standing yet unmet need to design methods of using the shipping containers in new and novel ways.

SUMMARY OF THE INVENTION

A building is provided, including at least two shipping containers, said containers comprising a top wall, a bottom wall, and two opposed side walls, said containers being mounted to a foundation in a spaced-apart, parallel manner, wherein portions of the adjacent inner side walls of said containers are removed, and further wherein a roof is attached to the top walls of said containers.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIG. 1 is a schematic diagram showing side (1A) and top views (1B and 1C) of a 10-story embodiment.

FIG. 2 is a schematic diagram showing a side view of a configuration according to an example embodiment, with the recessed-in option on either one side or both.

FIG. 3 is a schematic diagram showing a side view of a configuration according to an example embodiment, with the recessed-in option on either one side or both.

FIG. 4 is a schematic diagram showing a side view of a configuration according to an example embodiment, with the recessed-out option on either one side or both.

FIG. 5 is a schematic diagram showing a side view of a configuration according to an example embodiment, with the recessed-out option on either one side or both.

FIG. 6 is a schematic diagram showing a side view of a configuration according to an example embodiment, raised with additional containers and the option of vertical containers.

FIG. 7 is a schematic diagram showing a side view of a configuration according to an example embodiment, with stacked and/ or detached containers including an example roof configuration.

FIG. 8 is a schematic diagram showing a top view of a configuration according to an example embodiment, including attached or detached unit groups.

FIG. 9 illustrates the support detail according to example embodiments.

DETAILED DESCRIPTION

In an example embodiment of the present invention, metal shipping containers or other suitable metal containers are used in combination with traditional construction methods and materials in order to produce a hybrid-construction building. In example embodiments, the shipping container(s) serve as strong structural elements of the building. Unlike more traditional, all-metal pre-fabricated buildings, hybrid-construction buildings look and feel more like traditional buildings, yet still have the advantages of a pre-fabricated metal building, including faster construction, simplified labor, and reduced construction costs.

The cost of purchasing the shipping containers is less than that of traditional construction materials, such as bricks and mortar. Furthermore, using the containers as the structural element of a building requires a smaller and less expensive foundation than traditional materials.

In exemplary embodiments, the shipping containers are used as modular elements that can be combined and connected in a manner to form larger, stronger structural frames for a building.

The variety of examples embodied in FIGS. 1-9 is provided to illustrate a sample of arrangements. The examples of arrangements and configurations are not intended to limit the possibilities of interior or exterior configuration of containers or the use of interior spaces.

FIGS. 1-9 illustrate example embodiments of structures for residential use or light commercial spaces. According to example embodiments, the structures range from one to ten stories high, stacked either at a parallel or perpendicular to each other. Further examples are stacked at a 90 degree angle flush at the corners to faun a square or rectangle configuration, with the option to move one side or both sides in or out, up to eight feet depending on the interior or exterior space desired.

Referring now to FIG. 1, an example embodiment of a building 30 is provided. Containers 20 are set parallel to each other on raised support cubes or reinforced concrete slabs. Containers 10 are likewise parallel to each other and stacked on top of containers 20, so that containers 20 and containers 10 are perpendicular to each other. The corners of containers 10 and corners of containers 20 are flush with each other. Next, another set of containers 20 are stacked on top of containers 10 in the same manner, and so on and so forth. As shown in FIG. 1A, example embodiments are 10 stories high.

As shown in FIG. 1B, containers 10 and containers 20 are the same size, thereby forming a square configuration. In a further example embodiment, containers 10 and containers 20 are different sizes, forming a rectangle configuration, as shown in FIG. 1C.

Turning to FIGS. 2 & 3, a further example embodiment of a building 30 is provided. In FIG. 2, the corners of containers 20 are, for some stories, flush with the corners of containers 10, but depending on the need or desire for more or less space, the containers 20 and 10 are stacked in a manner such that the corners of containers 20 are recessed-in on either one side or both, up to 8 feet (see, e.g., stories 3, 5, and 6).

Turning to FIGS. 3, 4 & 5, a further example embodiment of a building 30 is provided. In this embodiment, the containers 20 are stacked on top of containers 10 so that additional space between containers 20 is provided. The corners of containers 20 and 10 are stacked in a manner on some stories such that the corners of containers 20 are recessed-out on either on one side or both, up to 8 feet (see, e.g., stories 1, 3, 7, and 9).

Turning now to FIG. 6, additional containers 20 are provided at the bottom of the building 30, stacked vertically, to gain open space or height below the building 30.

Turning next to FIG. 7, various roof 40 options are illustrated on various stacked and/or detached containers.

Turning now to FIG. 8, an example embodiment for a multi-family dwelling and/or a light commercial complex is provided. Multiple buildings 30 may be joined with additional containers 50.

The containers are mounted to a foundation in a spaced-apart, parallel manner, thereby forming the sides of one floor of the structure. In between the containers, the space is enclosed to form the rest of the interior space, using construction methods already known to those of skill in the art. Access between the containers and the enclosed space is provided via doors or other means cut into the containers.

The containers provide actual additional usable space. In order to further increase the usable space of the building, the steel containers need only be spaced further apart or closer together depending or desired space. A common roof is installed over the containers and the enclosed space. In further exemplary embodiments, doors and windows may be cut into either (or both) the steel containers or the enclosed space.

According to example embodiments, the structures range from one to ten stories high, stacked at a parallel and/or perpendicular and/or 90 degree angle flush at the corners to form a square and/or rectangle configuration with the option to move one side or both sides in or out up to eight feet depending on the interior or exterior space desired.

FIG. 9 illustrates example embodiments of support cubes and concrete slabs. The steel containers may be mounted on a raised platforms (support cubes), thereby rendering the completed structure ideal for water front construction. Typical concrete foundations will be installed to meet local code and have recessed areas for the container in an attempt to line-up the floor elevations, if desired.

In still further embodiments, the metal shipping containers with additional anchoring could serve as an emergency shelter in case of a serious storm or other inclement weather, such as earthquakes, tornadoes, and the like.

The foregoing specification is provided only for illustrative purposes, and is not intended to describe all possible aspects of the present invention. While the invention has herein been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof.

Claims

1. A building, comprising:

at least two shipping containers, said containers comprising a top wall, a bottom wall, and two opposed side walls, said containers being mounted to a foundation in a spaced-apart, parallel manner,

wherein portions of the adjacent inner side walls of said containers are removed, and

further wherein a roof is attached to the top walls of said containers.

2. The building of claim 1, wherein substantially all of the adjacent inner side walls are removed.

3. The building of claim 1, wherein the foundation is reinforced concrete slabs.

4. The building of claim 1, wherein the foundation is a raised platform.

5. The building of claim 1, further comprising at least one additional container, said additional container being stacked perpendicularly on the top walls of the at least two shipping containers.

6. The building of claim 1, further comprising at least on additional container, said additional container being stacked parallel on the top wall of one of the shipping containers.

7. A method of constructing a building, comprising:

providing at least two shipping containers, said containers comprising a top wall, a bottom wall, and two opposed side walls,

mounting said at least two containers to a foundation in a spaced-apart, parallel manner,

removing portions of the adjacent inner side walls of said containers, and

attaching a roof to the top walls of said containers.

8. The method of claim 7, wherein substantially all of the adjacent inner side walls are removed.

9. The method of claim 7, further comprising the step of stacking at least one additional container, perpendicularly on the top walls of the at least two shipping containers.

10. The method of claim 7, further comprising the step of stacking at least one additional container parallel to the top wall of one of the shipping containers.