DEMOUNTABLE CONSTRUCTION AND COMPONENT THEREFOR

Description

FIELD OF THE INVENTION

The present invention relates to a demountable frame building, and is particularly concerned with a connection member for connecting elongate frame members of the building.

BACKGROUND ART

The following discussion of the background art is intended merely to facilitate an understanding of the present invention; it should not be taken as an acknowledgement or admission that any of the material referred to is part of the common general knowledge.

Demountable frame buildings are known and comprise a plurality of elongate column members releasably connected to a plurality of elongate beam members. The frame buildings may also comprise roofing and flooring as well as cladding in a variety of forms that is applied to the frame to selectively close off the interior of the building.

In one arrangement one elongate column member and at least a first of the elongate beam members are connected together by a connection member.

One example of a demountable frame building according to this arrangement is described in Australian patent application AU2015201461 and its US equivalent U.S. Pat. No. 9,598,852. In this arrangement, a connector member of generally box shape has mating formations provided on two of the vertical faces of the box shape for sliding engagement with a hollow end of respective beam members. The mating formations are shaped to provide positive engagement between the connector member and beam members. Additionally, the mating formations may be secured in the hollow end portions by bolts. A horizontal face of the connector member has a male keying formation to engage a corresponding female keying formation formed on an end cap of the respective column member to prevent lateral and rotational movement of the end cap relative to the connector member. The end cap has a portion that extends exteriorly of the column member through which bolt holes are provided to secure the end cap to the connector member.

Other examples of connector members for demountable frame buildings are described in WO2011050492, U.S. Pat. Nos. 3,890,022, 3,921,360, 4,678,359, 6,338,226, 6,378,265, 6,390,719 and 63,516,955, all cited against U.S. Pat. No. 9,598,852.

Still other examples of connector members, and of connected frame members, are described in CN207296339U, WO96/00336 and U.S. Pat. No. 10,738,457 identified in an international-type search conducted by IP Australia.

Many of the structures described in the aforementioned prior art require frame members having complex profiles and/or connector members with complex manufacturing requirements.

Another known example of a connector member for a demountable frame building and having complex manufacturing requirements is illustrated in FIGS. 1a and 1b in assembled and exploded forms, respectively. FIGS. 1a and 1b illustrate a lower connector member 2. This connector member 2 has been used by the applicant and is designed for rectangular cross-section frame members. It is fabricated from five main steel components that are welded together: a hollow attachment portion 4 of rectangular cross-section and having two orthogonally disposed rectangular attachment faces 6 and 8, first and second end plates 10 and 12, a projecting L-profile receiving portion 14 that extends through the hollow attachment portion 4 and a drainage tube 16 that extends through the hollow attachment portion 4, welded to and supported by the end plates 10 and 12. A connector pipe 18 is welded to the drainage tube 16 and projects from the lower end of the attachment portion 4.

FIGS. 2a and 2b similarly illustrate in assembled and exploded form respectively a corresponding upper connector member 2′ that has been used by the applicant. It is also fabricated from five main steel components that are welded together: a hollow attachment portion 4′ of rectangular cross-section and having two orthogonally disposed rectangular attachment faces 6′ and 8′, first and second end plates 10′ and 12′, a projecting L-profile receiving portion 14′ that extends through the hollow attachment portion 4′ and a drainage tube 16′ that extends through the hollow attachment portion 4′, welded to and supported by the end plates 10′ and 12′. A drainpipe connector 18′ has an upper flange 20 that is welded to the lower face of the bottom end plate 12′ so as to project below the attachment portion 4′ between the arms 22′ and 24′ of the L-profile receiving portion 14′. Furthermore, the drainage tube 16′ has a lateral opening 26′ to which is welded one end of an L-shaped rainwater collector pipe 28′. The collector pipe 28′ passes through a slot 30′ in the wall of the attachment portion 4′ and a corresponding opening 31′ in the arm 22′ of the receiving portion 14′.

An example of a demountable frame building 32 of the type in which the connector members 2 and 2′ have been used is shown in FIGS. 3 and 4. FIG. 3 shows the frame building 32 in assembled form with floor panels in place, while FIG. 4 shows an exploded view without the floor panels.

The demountable frame building 32 comprises a pre-assembled rectangular base structure 34, a pre-assembled rectangular roof structure 36 and four identical corner column members 38. Each of the base structure 34, roof structure 36 and column members 38 may be assembled and otherwise prepared for use in a factory and then transported together in a flat knock-down state for assembly together on site. Alternatively, the overall assembly may also take place in a factory so that the assembled building 32 is shipped to site.

The base structure 34 comprises two longitudinal beam members 40 and two lateral beam members 42 all of rectangular cross-section and attached to the attachment portion 4 of a respective connector member 2 at each corner of the base structure. The rectangular cross-section of the beam members 40 and 42 corresponds approximately to the rectangular profile of the attachment faces 6 and 8 of the attachment portion 4. The end faces of each beam member butt up against and are welded to the respective attachment face 6 or 8. While welding is preferred, other attachment options may be considered including using fasteners.

The receiving portion 14 of each lower connector member 2 projects above the plane of the beam members 40 and 42, at right angles to the plane.

The base structure 34 further comprises an array of cross-members 44 that may be welded or otherwise secured at each end to the longitudinal beam members 40. The cross-members 44 may additionally be supported at each end by an inwardly projecting flange (not shown) on each longitudinal beam member 40. A floor system comprising individual floor panels 45, for example of plywood or particle board, is supported by the cross-members between the beam members 40 and 42.

The roof structure 36 comprises two longitudinal beam members 46 and two lateral beam members 48 all of rectangular cross-section and attached to the attachment portion 4′ of a respective connector member 2′ at each corner of the roof structure. The rectangular cross-section of the beam members 46 and 48 corresponds approximately to the rectangular profile of the attachment faces 6′ and 8′ of the attachment portion 4′. The end faces of each beam member butt up against and are welded to the respective attachment face 6′ or 8′. While welding is preferred, other attachment options may be considered including using fasteners.

The receiving portion 14′ of each upper connector member 2′ projects below the plane of the beam members 46 and 48, at right angles to the plane.

The roof structure further comprises roof panels 50 that together have a shallow gable profile that extends between the longitudinal beam members 46 from one lateral beam member 48 to the other. The roof panels 50 are supported on cross-members (not shown) similar to the cross-members 44 but having a triangular shape to reflect the gable profile of the roof panels. The roof structure cross-members are stich welded to flanges (not shown) extending inwardly from the longitudinal beam members 46. The roof panels 50 are supported below the profile of the upper face of the beam members 46 and 48.

The support flanges conveniently have an inner lip so as to form gutters at the longitudinal outer edges of the roof panels 50 to collect rainwater coming off the roof panels. The gutters are connected by openings 51 (one visible in FIGS. 3 and 4) in the end portions of the inner wall of each longitudinal beam 46 and connected to the rainwater collector pipe 28′ associated with each upper connector member 2′.

The column members 38 have a hollow rectangular cross-section and are each provided with a steel internal drainage pipe supported in the interior of the column member 38. The upper end 39 of a drainage pipe is visible in two of the column members 38 in FIG. 4. When the frame building is assembled the drainage pipe extends between the drainage tube 16 of the respective lower connector member 2 and the drainpipe connector 18′ of the respective upper connector member 2′ to provide drainage of water from the roof panels 50 to the exterior at ground level.

To assemble the frame building 32, any necessary ground preparation is performed, including, if necessary, levelling and the installation of drainpipes to take water from the outlet ends of the drainage tubes 16. Drainpipes or other rainwater control at ground level may not be necessary when the frame building is used as a temporary structure. The pre-assembled base structure 34 is then laid on the ground and any drainpipes are connected to the outlet end of the four drainage tubes 16. The four column members 38 are then mounted upright on the receiving portion 14 of the respective lower connector members 2. As each column member is lowered on to the receiving portion 14 the pre-assembled drainage pipe within it is engaged with the respective drainage tube 16.

The arms 14a and 14b of the receiving portion 14 are a close fit in the bottom end of the respective column members 38 and each column member is secured to the receiving portion by two pairs of bolts 52 passing through openings 53 in the inner faces of the bottom ends of the column members and screw threadedly engaging corresponding openings 54 in the arms 14a and 14b of the receiving portion.

The roof structure 36 is then lifted by crane or hoist and lowered onto the upper ends of the column members 38. As the roof structure is lowered, the arms 22′ and 24′ of the receiving portions 14′ slide into the upper ends of the column members 38 and the drainpipe connectors 18′ are engaged with the upper ends 39 of the pre-assembled drainage pipes in the column members.

The arms 22′ and 24′ of the receiving portion 14′ are a close fit in the upper end of the respective column members and each column member is secured to the receiving portion by two pairs of bolts 56 passing through corresponding openings 57 in the inner faces of the upper ends of the column members and screw threadedly engaging corresponding openings 58 in the arms 22′ and 24′ of the receiving portion.

The demountable frame building 32 is modular, having dimensions of, for example, about 6 m in length, about 2.5 m in width and about 3 m in height. In one embodiment, the external length and width may be the same as a standard shipping container (6058 mm×2438 mm). The basic building components, that is the base structure, the roof structure and the four corner column members, are of substantial mass. For example, the masses of the basic components may be as follows: base structure about 850 kg or about 1,000 kg including a floor; roof structure about 1000 kg including the roof panels; and each column member about 70 kg. The column members may be about 2.7 m in length or, for example, up to about 3 m if a higher ceiling is desired. An advantage of such a heavy demountable frame building structure is that it may be considered to be self-ballasting so that no tethering to the ground is required.

Once the aforementioned components are assembled flooring and modular wall components, including any of solid wall modules, door modules and window modules, may be secured to the building, both internally and externally as desired. U-channels (not shown) are conveniently provided on the opposed faces of the beam members of the base structure 34 and roof structure 36 to receive and support external wall, door and window panels. Any such panel may be lifted over the respective base U-channel into the corresponding roof U-channel and then aligned with the base U-channel and lowered into it while still remaining engaged with the roof U-channel. Additional securing, such as with fasteners and/or narrow support panels on the column members 38, may also be used.

Any of the modular components may include pre-assembled electrical power and lighting outlets and/or plumbing. The basic frame building components described above may be formed in mild steel, stainless steel or a combination of mild steel and stainless steel components depending on the environment. The roof panels 50 are formed of mild steel but other material could be used, and solid wall modules may be formed of sandwich panels (for example, foam between skin metal sheeting), optionally also supported between steel studs.

In some situations, such as in windy or potentially windy environments, some bracing of the demountable frame building may be required, such as by cross-bracing and/or by the use of load-bearing or structural walls.

The demountable frame building 32 may be enlarged by bolting one or more other such frame buildings to it at ground level and/or by sitting another such frame building atop it and bolting the respective base and roof beam members together. In the latter arrangement, the drainage pipes of the aligned column members would be connected together through the respective connection members.

The stacking of the demountable frame buildings described above has been found to be restricted by potential strength limitations of the fabricated connector members 2 and 2′.

It would be desirable to provide an alternative connector member for demountable frame buildings formed of a small number of parts and offering the possibility of greater strength.

SUMMARY OF THE INVENTION

According to the present invention, there is provided a demountable frame building connection member for connecting two elongate frame members of the frame building, the connection member comprising an attachment portion for attachment to a first of the elongate frame members and a receiving portion extending from the attachment portion for sliding engagement with a hollow end portion of a second of the elongate frame members, the receiving portion having at least one screw-threaded passage therein for receiving a locking member to secure the receiving portion in the hollow end portion of the second elongate frame member, wherein the attachment portion and receiving portion are integrally formed from a single piece of material and have respective rectangular cross-sections, the cross section of the receiving portion being smaller than and offset relative to that of the attachment portion to define a shoulder around the receiving portion on the attachment portion that is of greater depth on at least one side of the receiving portion, and wherein the at least one passage opens for receipt of the locking member on an opposite side of the receiving portion to said at least one side.

Generally, in use of the connector member, the first of the elongate frame members will be a beam member of the demountable frame building and the second of the elongate frame members will be a column member of the demountable frame building, and for convenience only the invention will be further described with this use in mind.

Further according to the invention there is provided a demountable frame building comprising a plurality of elongate column members and a plurality of elongate beam members connected together, wherein a first of the elongate column members has a hollow end portion of rectangular cross-section and said first elongate column member and a first and second of the elongate beam members are connected together by a connection member, the connection member comprising an attachment portion attached to the first and second elongate beam members and a receiving portion extending from the attachment portion and slidably engaged within the hollow end portion of the first elongate column member, the receiving portion having at least one screw-threaded passage therein aligned with a cooperating opening through the hollow end portion of the first elongate column member and receiving a screw-threaded locking member to secure the receiving portion in the hollow end portion of the first elongate column member, and further wherein the attachment portion and receiving portion of the connection member are integrally formed from a single piece of material and have respective rectangular cross-sections, the cross section of the receiving portion being smaller than the internal cross-section of the hollow end portion of the first elongate column member and being smaller than and offset relative to the cross-section of the attachment portion to define a shoulder around the receiving portion on the attachment portion for abutment with the hollow end portion of the first elongate column member, the shoulder being of greater depth on at least one side of the receiving portion, and wherein the at least one passage opens for receipt of the locking member on an opposite side of the receiving portion to said at least one side whereby screwing the locking member through the opening and into the passage acts to secure the hollow end portion of the first elongate column member against said opposite side of the receiving portion.

In one embodiment, the building comprises a pre-assembled base structure comprising plural elongate beam members with two of the beam members attached at each corner of the base structure to a respective one of the connection members, a pre-assembled roof structure of corresponding shape to the base structure and comprising plural elongate beam members with two of the beam members attached at each corner of the roof structure to a respective one of the connection members, and a respective column member at each corner slidingly engaged at each end with two opposed connection members of the base structure and roof structure. The base and roof structures may each be of rectangular shape and for convenience only are hereinafter described in this form. However other shapes are possible, such as triangular or polygonal with 5 or more sides and a corresponding number of corners and column members. By the present invention, the connection member can have considerably greater strength than one fabricated in the same engineering material, such as mild steel, stainless steel or aluminium, from multiple components welded or otherwise connected together. In some embodiments, the increase in strength in use of the connection member can be up to 8 times. This can permit stacking of a greater number of demountable frame buildings according to the invention, for example 3 or more, but can also alleviate or even eliminate any need for additional bracing of the demountable frame building through cross-bracing or the use of structural walls or wall members. This can greatly simplify the assembly of the demountable frame building and its subsequent disassembly.

In one embodiment, the connection member is milled from a single billet or piece of plate of engineering material. In one embodiment the milling is computer numerically controlled (CNC). Alternatively, the connection member could be cast.

Furthermore, by forming the connection member of the invention with a shoulder on the attachment portion that is of greater depth on at least one side, and thereby forming the receiving portion with a smaller cross-section than the internal cross-section of the hollow end portion of the first elongate column member, the receiving portion may be more readily slidably engaged with the hollow end portion. This is important for ease of assembly of the first elongate column member to the connector member.

The connection member of the invention may be used in essentially the same way as described above for the applicant's fabricated connection member, and that description may be considered as applicable, mutatis mutandis, to the present invention. Additional features of embodiments of the connection member of the invention are described below.

In one embodiment, the longitudinal edges between adjacent sides of the receiving portion are chamfered. This may also enhance the sliding engagement of the receiving portion in the hollow end portion of the first elongate column member.

In one embodiment, the receiving portion has at least one further screw-threaded passage for receiving a corresponding locking member in a side thereof adjacent to said opposite side, and the hollow end portion of the first elongate column member has a further cooperating opening(s) for the corresponding locking member, to additionally secure the receiving portion in the hollow end portion of the column member.

In one embodiment, the shoulder around the receiving portion on the attachment portion is of greater depth on the one side of the receiving portion and on an adjacent side thereof. In one embodiment of this arrangement and where the receiving portion has at least one further screw-threaded passage for receiving a corresponding locking member in a side thereof adjacent to said opposite side as described above, the adjacent side of the receiving portion on which the shoulder has a greater depth is opposite to the side on which the at least one further screw-threaded passage opens.

In one embodiment, the shoulder portion that is of greater depth has a depth that is about 2 to 3 times the depth of the remainder of the shoulder. In one embodiment, the shoulder has a depth of 6 mm to 10 mm, for example about 8 mm, except on the side or sides of the receiving portion where it has a greater depth. In one embodiment, the depth of the shoulder on the side or sides where it has a greater depth is in the range of 15 mm to 25 mm, for example about 20 mm.

In one embodiment, there are two or more screw-threaded passages, for example 3, spaced along the receiving portion in said opposite side of the receiving portion or in each of said opposite side and adjacent side of the receiving portion, and a corresponding number of openings in the hollow end portion of the first elongate column member and locking members.

In one embodiment, the locking member or each of the locking members is a bolt, but other forms of screw-threaded fastener may be used, for example a grub screw. The locking member may be formed of stainless steel.

In one embodiment, the receiving portion of the connection member has a length that is at least about 1.5 times the length of the attachment portion, for example 1.5 to 2.5 times. In one embodiment, the receiving portion of the connection member has a length that is at least about 1.5 to about 1.75 times the length of the attachment portion.

In one embodiment, the receiving portion of the connection member when engaged with the hollow end portion of the column member extends a substantial way into the column member, for example by from 5% to 20% of the length of the column member. In one embodiment, the receiving portion of the connection member when engaged with the hollow end portion of the column member extends into the column member by at least 10% of the length of the column member. In one embodiment, the receiving portion has a length of about 180 mm to about 500 mm, for example about 270 mm to about 400 mm. In a particular embodiment the receiving portion has a length of about 330 mm. The column member may in some embodiments have a length in the range of 2.7 m to 3 m, or even 4 m if a higher ceiling is required.

In one embodiment, the connection member has a longitudinal passage for drainage purposes through the attachment and receiving portions from one end to the other. The or each screw-threaded passage for receiving a locking member may extend laterally towards the drainage passage, but in one embodiment is blind and does not open into the drainage passage. This may alleviate leakage of rainwater from the drainage passage. In one embodiment, the drainage passage extends along the central axis of the attachment portion.

In one embodiment, the drainage passage carries rainwater directly through the connection member. This is possible where the connection member is formed in a rainwater resistant material such as stainless steel. In another embodiment, a sleeve is provided in the drainage passage to carry the rainwater from one end of the drainage passage to the other. This arrangement is advantageous where the material of the connection member is subject to corrosion by the rainwater, for example when it is formed of mild steel, and/or where the drainage passage is interrupted by other openings such as the aforementioned at least one screw-threaded passage for receiving a locking member. The sleeve may be formed of any suitable material, including plastics or metal such as mild steel or stainless steel.

In one embodiment, each end of the drainage passage through the connector member, or one of them, is screw threaded to receive a connector pipe. In another embodiment, each end of the drainage passage through the connector member, or one of them, is enlarged to slidably receive the end portion of a drainage tube therein.

In one embodiment, a side port opens into the drainage passage from a side face of the attachment portion. In a connector member associated with the roof structure, the side port may be connected to a collector pipe to receive rainwater off the roof panels. In one embodiment, the side port is screw-threaded to threadedly receive a connector of the collector pipe.

In one embodiment, the distal end portion of the receiving portion is chamfered on at least one side face to further facilitate engagement of the receiving portion with the hollow end portion of the column member. This is particularly advantageous for upper connection members associated with a roof structure of the demountable frame building, which is lowered onto four corner column members by crane or hoist, but may not be required for lower connection members associated with a base structure of the demountable frame building.

In one embodiment, the chamfering is provided on two adjacent side faces of the distal end portion of the receiving portion.

Whether on one or two side faces of the distal end portion of the receiving portion, the chamfer may not be consistent across the side face. For example, it may increase from one edge to the other; at the one edge there may be no chamfer. In one embodiment when the chamfer is provided on two adjacent side faces of the distal end portion, the two chamfers may increase to a maximum at the common edge.

In one embodiment, each column member when fully engaged with the respective connection member extends at least substantially flush with the attachment portion. In such an embodiment the wall thickness of the hollow end portion of the column member may be the same as the minimum depth of the shoulder on the attachment portion, such as in the range of 6 mm to 10 mm, for example about 8 mm.

In one embodiment, a shim is provided adjacent the shoulder on the one side face of the receiving portion of the connector member associated with the shoulder portion of greater depth. In one embodiment where the shoulder portion of greater depth is also on the adjacent side face of the receiving portion, a second shim is also provided adjacent the shoulder on that adjacent side face. The or each shim helps to guide the sliding engagement of the receiving portion into the hollow end portion of the column member, and is particularly advantageous on the connection members associated with the roof structure.

In embodiments, the or each shim may have one or more of the following features: integrally formed with the receiving portion; longitudinally spaced from the shoulder; centrally disposed across the width of the respective side face of the receiving portion; a width in the range of about 7 to 20% of the width of the respective side face; a depth about 50%, for example 40% to 55%, of the associated shoulder portion of greater depth; tapered towards the distal end of the receiving portion to provide a ramp surface for the column member adjacent the shoulder.

In one embodiment including the aforementioned shim or shims having a ramp surface, the connector member has a drainpipe connector connected to and projecting from a distal end face of the receiving portion, and the spacing of the shoulder from the end of the ramp surface closest to the shoulder is arranged such that the receiving portion is correctly aligned in the column member by the time the drainpipe connector engages the upper end of a drainage tube through the column member.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention and the best mode for carrying out the invention will now be described by way of example with reference to the accompanying drawings. In the drawings:

FIGS. 1a and 1b are perspective views of a lower connector member for a demountable frame building according to the prior art, in assembled and exploded form, respectively;

FIGS. 2a and 2b are perspective views of an upper connector member for a demountable frame building according to the prior art, in assembled and exploded form, respectively;

FIG. 3 is a perspective view of an assembled demountable frame building using the prior art connector members of FIGS. 1 and 2, including a flooring system;

FIG. 4 is an exploded perspective view of the demountable frame building of FIG. 3, with the flooring system omitted;

FIGS. 5a and 5b are top and bottom perspective views, respectively, from opposite sides of one embodiment of a lower connector member according to the invention;

FIGS. 6a and 6b are top and bottom perspective views, respectively, from opposite sides of one embodiment of an upper connector member according to the invention;

FIGS. 7a and 7b are perspective views of one embodiment of a column member with the lower and upper connector members of FIGS. 5 and 6, in exploded and assembled form, and FIG. 7c is the same view as FIG. 7b but with the outer tube of the column member removed for clarity only to reveal the drainage tube;

FIG. 8 is a perspective view of one embodiment of a floor structure for a demountable frame building according to the invention using the lower connector members of FIG. 5;

FIG. 9 is a perspective view of one embodiment of a roof structure for a demountable frame building according to the invention using the upper connector members of FIG. 6; and

FIG. 10 is a perspective view of one embodiment of a demountable frame building according to the invention, using the column members, floor structure and roof structure of FIGS. 7, 8 and 9 respectively.

BEST MODE(S) FOR CARRYING OUT THE INVENTION

In the following description, for convenience only and where appropriate, similar components will be depicted by the same reference numeral followed by a prime (′).

Two embodiments of the best mode for carrying out the invention of the connector member are shown in FIGS. 5a and 5b and FIGS. 6a and 6b respectively, and one embodiment of the best mode for carrying out the invention of the demountable frame building incorporating these embodiments of connector member is shown in FIGS. 7 to 10.

Referring to FIGS. 5a and 5b, the lower connector member 60 comprises an attachment portion 62 and a receiving portion 64. The connector member is CNC milled from a single billet of mild steel or stainless steel. The choice of engineering material depends in part on the environment in which the connector member will be used.

The attachment portion 62 and receiving portion 64 each have a generally rectangular cross-section, but that of the receiving portion 64 is smaller than that of the attachment portion 62 to define a shoulder 66 around the receiving portion on the attachment portion. The receiving portion 64 is axially offset relative to the attachment portion 62 such that the shoulder 66 has a first portion 68 along a first side 70 of the receiving portion and a second adjacent portion 72 along an adjacent second side 74 of the receiving portion that are of greater width than the remainder of the shoulder 66. The ratio of the widths of the first and second shoulder portions 68 and 72 to the remainder of the shoulder 66 is about 2.5:1.

The attachment portion 62 has four flat side faces of which two adjacent side faces on the opposite sides to the shoulder portions 68 and 72 of greater width form attachment faces 76 and 78 for securing elongate beam members (see FIGS. 8 and 10) thereto. In this embodiment, the beam members are welded to the attachment faces.

The attachment faces 76 and 78 extend between a proximal end 80 of the connector member 60 and an intermediate portion 82 of the respective side faces adjacent to the shoulder portions 68 and 72 and having rounded edges 84. The attachment faces 76 and 78 have a width and length (from the proximal end 80 to the intermediate portion 82) that substantially equate to the outer cross-sectional dimensions of the beam members.

The receiving portion 64 has a length that is about 1.5 times the length of the attachment portion 62 from the proximal end 80 of the connector member 60 to the shoulder 66, or about 2.0 to about 2.5 times the length of the attachment faces 76 and 78 from the proximal end 80 to the intermediate portion 82.

The sides of the receiving portion 64 are flat but have chamfered edges 92 to facilitate the sliding insertion of the receiving portion into a column member 93 (see FIG. 7a) as described hereinafter.

Three equally longitudinally spaced lateral screw-threaded openings 86 (the screw thread is omitted from FIG. 5a for convenience only) are provided in each of side faces 88 and 90 of the receiving portion 64 opposite to the sides 70 and 74, respectively. The openings 86 receive bolts to secure a column member 93 on the receiving portion, as described hereinafter.

A longitudinal drainage passage 94 extends through the attachment and receiving portions 62 and 64 from the proximal end 80 to a distal end 96 of the connector member 60. The drainage passage 94 is axially centred on the attachment portion 62 and is therefore axially offset in the receiving portion 64. The opening of the drainage passage 94 at the proximal end 80 is screw-threaded to optionally receive a connector pipe 95 (see FIGS. 7a-c). The opening of the drainage passage 94 at the distal end 96 is smooth to slidingly receive a drainage tube 118 of the column member 93 as described hereinafter.

A drainage sleeve (not shown) may extend along the drainage passage 94 to protect the drainage passage and the engineering material of the connector member 60 from corrosive effects of rainwater passing through the connector member but is not necessary in all environments or when the engineering material is stainless steel.

The screw-threaded openings 86 are laterally aligned with the drainage passage 94, but they are blind and therefore do not open into the drainage passage.

Referring to FIGS. 6a and 6b, the upper connector member 60′ is very similar to the lower connector member 60, but is used relatively inverted. It comprises an attachment portion 62′ and a receiving portion 64′. The connector member 60′ is CNC milled from a single billet of mild steel or stainless steel. The choice of engineering material depends in part on the environment in which the connector member will be used.

The attachment portion 62′ and receiving portion 64′ each have a generally rectangular cross-section, but that of the receiving portion 64′ is smaller than that of the attachment portion 62′ to define a shoulder 66′ around the receiving portion on the attachment portion. The receiving portion 64′ is axially offset relative to the attachment portion 62′ such that the shoulder 66′ has a first portion 68′ along a first side 70′ of the receiving portion and a second adjacent portion 72′ along an adjacent second side 74′ of the receiving portion that are of greater width than the remainder of the shoulder 66′. The ratio of the widths of the first and second shoulder portions 68′ and 72′ to the remainder of the shoulder 66′ is about 2.5:1, with the shoulder portions 68′ and 72′ in the described embodiment having a depth of about 20 mm.

The attachment portion 62′ has four flat side faces of which two adjacent side faces on opposite sides to the shoulder portions 68′ and 72′ of greater width form attachment faces 76′ and 78′ for securing elongate beam members (see FIGS. 9 and 10) thereto. In this embodiment, the beam members are welded to the attachment faces.

The attachment faces 76′ and 78′ extend between a proximal end 80′ of the connector member 60′ and an intermediate portion 82′ of the respective side faces adjacent to the shoulder portions 68′ and 72′ and having rounded edges 84′. The attachment faces 76′ and 78′ have a width and length (from the proximal end 80′ to the intermediate portion 82′) that substantially equate to the outer cross-sectional dimensions of the beam members.

The receiving portion 64′ has a length that is about 1.5 times the length of the attachment portion 62′ from the proximal end 80′ of the connector member 60′ to the shoulder 66′, or about 2.0 to about 2.5 times the length of the attachment faces 76′ and 78′ from the proximal end 80′ to the intermediate portion 82′.

The sides of the receiving portion 64′ are flat but have chamfered edges 92′ to facilitate the sliding insertion of the receiving portion into a column member 93 as described hereinafter.

Three equally longitudinally spaced lateral screw-threaded openings 86′ (the screw thread is omitted from FIG. 6a for convenience only) are provided in each of side faces 88′ and 90′ of the receiving portion 64′ opposite to the sides 70′ and 74′, respectively. The openings 86′ receive bolts to secure a column member 93 on the receiving portion, as described hereinafter.

A longitudinal drainage passage 94′ extends through the attachment and receiving portions 62′ and 64′ from the proximal end 80′ to a distal end 96′ of the connector member 60′. The drainage passage 94′ is axially centred on the attachment portion 62′ and is therefore axially offset in the receiving portion 64′. The opening of the drainage passage 94′ at the distal end 96′ is screw-threaded to receive a connector pipe 98 (see FIG. 9). The opening of the drainage passage 94′ at the proximal end 80′ is smooth to optionally slidingly receive a drainage pipe connector from a superposed lower connector member 60 as described hereinafter.

A drainage sleeve (not shown) may extend along the drainage passage 94′ to protect the drainage passage and the engineering material of the connector member 60′ from corrosive effects of rainwater passing through the connector member but is not necessary in all environments or when the engineering material is stainless steel.

The screw-threaded openings 86′ are laterally aligned with the drainage passage 94′, but they are blind and therefore do not open into the drainage passage.

The drainage passage 94′ of the upper connector member 60′ has a side port 100 through the attachment portion 62′ that is screw-threaded at its outer end in the attachment face 78′ to threadedly receive a right-angle collector pipe 102.

At the distal end 96′ of the receiving portion 64′ of the upper connector member 60′ the adjacent side faces 70′ and 74′ of the receiving portion are chamfered at 104 and 106, respectively. The chamfers 104 and 106 are graded, extending from a maximum at the common side edge 92′ to zero at the respective outer side edges 92′. The chamfers 104 and 106 facilitate the sliding insertion of the receiving portion 64′ into the column member 93 in use.

Respective shims or ramp members 108 and 110 are also provided on the adjacent side faces 70′ and 74′ of the receiving portion 64′ of the upper connector member 60′. The shims 108 and 110 help to guide the column member into lateral position as the receiving portion 64′ is approaching maximum sliding insertion into the column member as described hereinafter.

The shims 108 and 110 are identical and, for convenience only, just one will be described. The shim 108 on the side face 70′ is adjacent the respective shoulder portion 68′ but spaced from it and is centrally disposed between the respective side edges 92′. The shim 108 is elongate along the length of the receiving portion, and relatively narrow with a width about 10% of the width of the side face 70′.

The shim 108 has a ramp surface 112 at its end remote from the shoulder portion 68′ leading into a portion 114 of maximum depth. The shim portion 114 has a maximum depth of about one half the depth of the shoulder portion 68′.

The spacing of the upper end 116 of the ramp surface 112 from the shoulder portion 68′ is designed relative to the projection length of the connector pipe 98 engaged with the distal end 96′ of the receiving portion 64′ such that the connector pipe 98 is aligned with the upper end of a drainage tube 118 (see FIG. 7c) in an associated column member 93 by the time the upper end of the column member engages the portion 114 of the shim 108 as the receiving portion 64′ is slidingly received in the upper end of the column member.

In FIG. 7a, a lower connector member 60 and an upper connector member 60′ are shown substantially aligned with a respective column member 93 for sliding engagement with the respective receiving portions 64 and 64′. However, in practice, before this happens, the lower connector member 60 is welded to longitudinal and lateral beam members 120 and 122 of a base structure 124 (see FIG. 8) and the upper connector member 60′ is welded to longitudinal and lateral beam members 126 and 128 of a roof structure 130 (see FIG. 9). The construction of the base structure 124 and roof structure 130 can occur in a factory to ensure the welding is of a satisfactory standard.

Referring to FIG. 8, the base structure 124 comprises two longitudinal beam members 120 and two lateral beam members 122 all of rectangular cross-section, with one of each attached to the attachment portion 62 of a respective lower connector member 60 at each corner of the rectangular base structure. The rectangular cross-section of the beam members 120 and 122 corresponds approximately to the rectangular profile of the attachment faces 76 and 78 of the attachment portion 62, and in this embodiment the external dimensions are 125 mm×125 mm. An end face of each beam member butts up against and is welded to the respective attachment face 76 or 78.

The receiving portion 64 of each lower connector member 60 projects above the plane of the beam members 120 and 122 of the base structure 124, at right angles to the plane.

The base structure 124 further comprises an array of spaced cross-members 132 that are welded at each end to the longitudinal beam members 40. The cross-members 44 may additionally be supported at each end by an inwardly projecting flange (not shown) on each longitudinal beam member 40. A floor system 134 (see FIG. 10) comprising individual flooring sheets is supported by and attached to the cross-members 132 before or after the base structure 124, roof structure 130 and column members 93 are assembled.

Referring to FIG. 9, the roof structure 130 comprises two longitudinal beam members 126 and two lateral beam members 128 all of rectangular cross-section, with one of each attached to the attachment portion 62′ of a respective upper connector member 60′ at each corner of the rectangular roof structure 130. The base structure 124 and roof structure 130 are the same shape and size. The rectangular cross-section of the beam members 126 and 128 corresponds approximately to the rectangular profile of the attachment faces 76′ and 78′ of the attachment portion 62′, with the same dimensions as the cross-section of the beam members 120 and 122 of the base structure 124. An end face of each beam member butts up against and is welded to the respective attachment face 76′ or 78′.

The receiving portion 64′ of each upper connector member 60′ projects below the plane of the beam members 126 and 128 of the roof structure 130, at right angles to the plane.

The roof structure 130 further comprises roof panels 134 formed of mild steel that together have a shallow gable profile that extends between the longitudinal beam members 126 from one lateral beam member 128 to the other. The roof panels 134 are supported on cross-members (not shown) extending between and welded to an inner flange 135 extending inwardly from each longitudinal beam member 126. The roof structure cross-members are similar to the cross-members 132 of the base structure, but have inclined upper faces to reflect the gable profile of the roof panels 134. The roof panels are held in place by stitch welding to the flanges 135. The roof panels 134 are supported below the profile of the upper face of the beam members 126 and 128.

The flanges 135 have an inner lip so as to form gutters at the longitudinal outer edges of the roof panels 134 to collect rainwater coming off the roof panels and the inner face 138 of each longitudinal beam member 126 has an opening 140 at each end to collect the rainwater from the gutters. The right-angle collector pipe 102 associated with the adjacent connector member 60′ extends through the end portion of the longitudinal beam member 126 and has a distal end 142 that is welded to the beam member at the opening 140 to carry the rainwater from the gutter to the drainage passage 94′ of the connector member.

Referring to FIGS. 7a-c, the four column members 93 associated with respective corners of the base structure 124 and roof structure 130 are identical. Each column member comprises a mild steel tube 144 of a rectangular cross-section that is substantially the same size and shape as the external cross-section of the intermediate portions 82 and 82′ of the connector members 60 and 60′ at the shoulder 66 or 66′ of each connector member.

The column member 93 has a length dependent on the desired spacing of the roof structure 130 from the base structure 124, for example about 2.7 m or 3 m. The wall thickness is substantially the same as the smaller depth of the shoulder 66 or 66′ of the respective connector member 60 or 60′, for example about 8 mm.

At each end the column member 93 has an array of three longitudinally spaced openings 146 in each of the two inner faces 148 (in use) of the column member. The openings 146 are aligned in use with respective screw-threaded openings 86 or 86′ of the associated connector member 60 or 60′ when the receiving portion 64 or 64′ of the connector member is fully received in the column member. Referring to FIG. 10 each of the openings 146 receives a respective locking bolt 150 when the paired openings 146 and 86 or 86′ are aligned following insertion of the respective receiving portion 64 or 64′ into the column member 93. Each locking bolt 150 has a head 152 and a threaded shank (not visible) and the openings 146 are sized to closely (but not screw-threadedly) receive the respective shank as the shank is screw threadedly engaged with the receiving portion opening 86 or 86′. The head 152 of each locking bolt 150 is received in a respective recessed washer (not shown) so as to spread the load of the head on the column member end portion around the opening 146. The washer may be formed of any suitable material, such as stainless steel.

Referring again to FIGS. 7a and 7b, each inner face 148 of the column member 93 also has two spaced slots 156 for receiving a respective support tab 158 of the drainage tube 118 (see FIG. 7c) and optional pairs of screw threaded openings 160 for securing a chair rail (not shown) to it by means of bolts.

In FIG. 7c the drainage tube 118 is shown separated from the mild steel tube 114 of the column member 93 and connected to the opposed lower and upper connector members 60 and 60′ for clarity only. In practice, the drainage tube 118 would be pre-assembled in the tube 144 and the tabs 158 would be seated in and welded to the slots 156 prior to the connector members 60 and 60′ being engaged with it. In effect, FIG. 7c shows the connector members 60 and 60′ fully engaged with the column member 93 but with the outer skin of the column member formed by the tube 144 deleted in the figure for clarity.

The drainage tube 118 may be formed of mild steel or stainless steel according to the environment in which it is used and has a connector tube 164 screw-threadedly engaged with it at the lower end 162 to slidingly engage into the drainage passage 94 of the lower connector member 60 at the distal end 96 of the receiving portion 64. At its upper end 166 the drainage tube 118 slidingly receives in it the projecting portion of the connector pipe 98 screw-threadedly engaged with the drainage passage 94′ through the connector member 60′ at the distal end 96′ of the receiving portion 64′.

Referring to FIG. 10, to assemble the demountable frame building 168, the pre-assembled base structure 124 is laid on level ground by crane or hoist. Any drainage system in the ground at the location of use is connected to the outlet end of the four drainage passages 94 at the proximal end 80 of the four lower connector members 60. However, usually no such ground drainage system is required for a demountable building and the outlet end of each drainage passage 94 will merely open to the ground. The four column members 93 are then slidingly engaged with the receiving portion 64 of the respective lower connector members 60. This may be done manually and, as each column member is lowered on to the respective receiving portion 64, the lower connector tube 164 of the pre-assembled drainage tube 118 within the column member is manually slidingly engaged into the upper end of the respective drainage passage 94 at the distal end 96 of the receiving portion.

The receiving portion 64 has some play in the lower end of the respective column member 93 to facilitate the sliding engagement between the two as a function of the deeper shoulder portions 68 and 72 and the column member can be manually manoeuvred on the receiving portion 64 to align each of the openings 146 in the lower end of the column member with its respective screw-threaded opening 86 in the receiving portion 64. Once the pairs of openings 146 and 86 are aligned the lower end of the column member is secured to the receiving portion by the six locking bolts 150. Each bolt is provided with its respective recessed washer and its shank is passed through the respective opening 146 before being screw threadedly engaged with the respective opening 86.

When all of the pairs of openings 146 and 86 are aligned, the lower end face of the column member 93 abuts the shoulder 66 of the attachment portion 62 of the respective connector member 60 and the lower end of the column member extends flush with the four flat side faces of the intermediate portion 82 of the connector member 60.

The roof structure 130 is then lifted by crane or hoist and lowered onto the upper ends of the column members 93. As the roof structure is lowered, the receiving portions 64′ of the four upper connector members 60′ slide into the upper ends of the column members, guided in part by the chamfered distal end 96′ of the receiving portion.

The receiving portion 64′ has some play in the upper end of the respective column member 93 to facilitate the sliding engagement between the two as a function of the deeper shoulder portions 68′ and 72′ but the suspended roof structure 130 cannot be readily manually manoeuvred on the column members to align each of the openings 146 in the upper end of the column members with its respective screw-threaded opening 86′ in the receiving portions 64′. Instead, as the roof structure 130 is lowered the ramp surface 112 of each shim 108 on the receiving portions 64′ causes the receiving portions to gradually be correctly aligned in the upper ends of the column members 93.

The alignment of each receiving portion 64′ in the upper end of its associated column member 93 also causes the associated connector pipe 98 to align with the upper end of the drainage tube 118 in the column member so that the connector pipe can slidingly engage the drainage tube as the receiving portion 64′ is fully lowered into the column member.

Once all six pairs of openings 146 and 86′ are aligned the upper end of each column member 93 is secured to the receiving portion 64′ by the six locking bolts 150. Each bolt is provided with its respective recessed washer and its shank is passed through the respective opening 146 before being screw threadedly engaged with the respective opening 86′.

When all of the pairs of openings 146 and 86′ are aligned, the upper end face of the column member 93 abuts the shoulder 66′ of the attachment portion 62′ of the respective upper connector member 60′ and the upper end of the column member extends flush with the four flat side faces of the intermediate portion 82′ of the connector member 60′.

Once fully assembled as described, the demountable frame building 168 is self-ballasting as a result of its mass so that no tethering is required and sufficiently rigid that no bracing is required. The rigidity is provided by the engagement of the connector members 60 and 60′ with the respective beam members and column members 93.

Once the demountable frame building has been assembled as described flooring and modular wall components, including any of solid wall modules, door modules and window modules, may be secured to the building, both internally and externally as desired.

U-channels 170 (shown in FIG. 10) are welded or bolted on the opposed faces of the beam members of the base structure 34 and roof structure 36 to receive and support external wall, door and window panels. Any such panel may be lifted over the respective bottom U-channel 170 into the corresponding upper U-channel 170 and then aligned with the bottom U-channel and lowered into it while still remaining engaged with the upper U-channel. Additional securing of the panels, such as with fasteners, may also be used. Side panels (not shown) may also be secured to the column members 93 to overlap the vertical edges of the wall, door and/or window panels.

The demountable frame building 168 may be enlarged by bolting one or more other such frame buildings to it at ground level and/or by sitting another such frame building atop it and bolting the respective base and roof beam members together. In the latter arrangement, the drainage tubes 118 of the aligned column members 93 would be connected together through the respective connection members 60 and 60′.

While several embodiments of the invention have been described, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit or scope of the invention. Accordingly, it is intended to claim all such changes and modifications as falling within the scope of the invention.

It is apparent from the above, that the arrangements described are applicable to demountable frame buildings and to modular components for them.

Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.