Abstract:
A small, heavy duty, transportable building having pre-manufactured panel assemblies made out of magnesium oxide for the floor, wall and roof that are quickly fastened together, on site, using common metal screws. All building materials are inorganic for extreme mold and mildew resistance. Furthermore, the building panels are configured and fastened together for inherent insulative fire and flood resistant properties. Commercial metal strut forms an economic protective perimeter around the magnesium oxide surface panels, and offer a fastening means to adjoining panels. The uses of the building (bunker, enclosure, shelter, shed, little-house, etc. . . . ) are myriad and not intended to be limited in usefulness. In addition, the building configurations and square footage options are limitless, single wide building ways, storied if desired. The design also allows manufacturing of the panel assemblies with common, hand tools, power tools, and welding equipment. No crane is needed for building erection.

Description:
REFERENCES CITED 
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       BACKGROUND 
       [0002]    A need exists for small economic, rugged, insulated, transportable, fire and water resistant, buildings, for security of persons and/or property. 
         [0003]    A further need exists for flexible building configurations designed in modular lengths to allow for custom solutions to meet additional owner requirements. 
         [0004]    An additional need exists that these buildings may be quickly erected manually, on site, without the need of mixed and cured concrete using common hand tools. 
         [0005]    The present flexible embodiments meet these needs. 
       BRIEF SUMMARY OF INVENTION 
       [0006]    The present embodiments generally relate to floor, wall, roof, and pre-manufactured building structures resistant to abnormal or extreme external or internal conditions. The structures of the present invention are useful in applications where a transportable, building requires a high degree of fire, mold, termite, and water resistant performance. 
         [0007]    Furthermore, the building design is economic, simple, rugged, and provides security. It can be assembled with  2  persons, without a crane on site and no mixed concrete is required for installation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The detailed description will be better understood in conjunction with the accompanying drawings as follows: 
           [0009]      FIG. 1  depicts a building (partially shown for structural clarity) formed according to one embodiment. Other embodiments have a similar gable end width, but different lengths and door and window penetrations determined by end user. 
           [0010]      FIG. 2  depicts a sidewall assembly (without window perforation) according to one or more embodiments. End wall assembly panels are similar, and in one embodiment, the design has a slope and plateau upper edge section(s). Sliding doors are made in a similar manner. 
           [0011]      FIG. 2A  depicts a vertical side section of a sidewall or door assembly according to one or more embodiments showing the metal strut cross section, weld captivating feature, at least one or more commercially available layered glass reinforced MGO boards. Also shown are the air gaps and metal screen thermal break surface. 
       
    
    
       [0012]    The present embodiments are detailed below with reference to the listed Figures. 
       DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0013]    Before explaining the present design in detail, it is to be understood that the enclosure is not limited to the particular embodiments and that it can be practiced or carried out in various ways. 
         [0014]    In an embodiment of the invention, pre-fabricated multi-layered, MGO wall panel assemblies&#39; (or structures) are joined side to side on top of level adjusted subfloor panel assemblies, finished floor concrete, or concrete walls (block or poured). Fasteners can join the adjoining metal perimeter edges together. Multiple wall panels can be straight or at various angles, that can be joined to form the outer walls of a building. 
         [0015]    The building can include single story and second story wall structures. For single story building embodiments, the design and construction is seismic and wind resistant to a maximum wind gust of 156 MPH (CATAGORY 4 HURRICANE 130-156 MPH). 
         [0016]    In another embodiment of the invention that forms the basic protective shell, all electrical conduit, supply plumbing, and other human conveniences may be installed on the inside surface of the wall(s) and or roof truss(es). 
         [0017]    A building exhaust vent or vents may be installed in the center roof support structure and can exhaust out the ends of the gables. The design allows for 3″ type B, double walled, gas vent that has a maximum OD of up to 4″. The inner area of the roof support channel(s) may be used as a combination space for electrical cables, wires, water and gas piping, air ducting for HVAC purposes and insulation. 
         [0018]    A door or double doors can be inserted in place of one or two of the wall panels respectively, creating an easy ingress or egress to the building where needed. 
         [0019]    The building has an all-metal skeletal frame construction in combination with high heat resistant layered glass reinforced MGO boards for fire resistance in the case of an adjacent burning building or other burning fuel source. 
         [0020]    The building, in all embodiments, will survive at least 3 feet of wet snow on the roof, providing a strong building for shelter against the heaviest snow and ice accumulations. 
         [0021]    Single level building embodiments, will survive a category 4 hurricane when secured to 36″ deep set stakes at all designed locations or securely fastened to a concrete foundation. 
         [0022]    An assembled 8′×12′ building (or smaller) can be quickly airlifted, via a 3″ pipe (or 4″ tube) through the gable vent holes, to a site of a natural disaster and set in place and serve as a triage location for victims of a mudslide, tornado or earthquake stricken area. 
         [0023]    The 8′×12′ building (or smaller) is economical to move, with easy wide span (&gt;4′-6″)×9′ long forklift access for lifting of the entire building without disassembly if desired. 
         [0024]    In various embodiments, the building may be assembled, before delivery to the end user with various optional electrical and plumbing enhancements, thus allowing the building to be in a more advanced finished state, verses an onsite-erected building from a palleted kit. 
         [0025]    The bare 8′×8′ building weighs approximately 2,100 lbs, and can be quickly deployed as an emergency shelter(s) after a natural disaster, using helicopter air lift or pickup truck transport directly to the site(s) of greatest need. 
         [0026]    Various embodiments may be optionally outfitted with basic utilities and fixtures to meet international codes for safe human habitation. An egress-sized window (or smaller) may be installed in any vertical wall in the building. An outer building perimeter, semi vented, skirt required by many local codes protects the sub floor area water lines from freezing damage. 
         [0027]    Simple expansion in predesigned configurations of initial floor space configuration is allowable based on future need. Alternately, contraction of floor space future requirements is similarly possible. 
       The Following Definitions are Used Herein. 
       [0028]    The term “door” as used herein can refer to a conventional sliding or pivoting door to the building. 
         [0029]    The term “fasteners” as used herein can refer to rivets, bolts, staples, as well as screws. 
         [0030]    The term “filleted” as used herein can refer to corners that are cut to a rounded or chamfered edge. 
       Turning Now to the Figures for Detail Explanation; 
       [0031]      FIG. 1  depicts a building  1300  with some roof panels  108  and side panels  123  removed for structural clearness, formed according to one embodiment. Other embodiments can have a similar gable end width defined by end panels  125 , but different lengths. 
         [0032]    At a minimum, one door  104  and window penetration is installed in door. 
         [0033]    The present shown building  1300 , embodied is a dash 06 configuration, nominally measuring 24′ in length, representing the width of six 4′ wide floor panels  120  and side panels  123  along the length. The allowable straight length is not limitless. It can meet performance specifications if a longer length is wanted only if the building is shaped like an “L” with the short leg being two panels wide. Then the structure may be continued for up to an additional six panels in length. Continue this pattern, building to either side, up to a maximum of six panels in length allowing foot print configurations that are unlimited. Building to the side is necessary to support lateral high wind loads or seismic loads. 
         [0034]    The embodiment shows some of the required levelers  145  at the ends of linear floor support  121  to allow the floor to be adjusted plum flat to an uneven ground placed, Concrete Masonry Unit  112  (CMU  112 ) supporting surface. Anchor stakes  103  can be driven into undisturbed or compacted soil at all building corners at a minimum. Holdown means may be accomplished with chain and turnbuckles  102 . For maximum wind and seismic load resistance, install anchor stakes  103  and filleted holdowns at all leveler  145  support points. An outer building perimeter, semi vented, skirt  111  protects the sub floor area water lines from freezing damage. The PVC skirt  111  also blocks animals from intrusion into the subfloor area and provides some insulation. 
         [0035]    The building can be stacked one level up (not shown). This allows an upper second story configuration to support the concept of modular building design. 
         [0036]    Multiple drill point screws  155  can be drilled into the end panels  125  through clearance holes on the side panels  123 . Embodied additional screws fasten the end floor panel  120  to end panels  125  through a T bracket  138 . Steel holdown straps can be welded to floor beam support  121  and can be screwed into floor panels  120 , side panels  123  and corner column strut  132  where a door exists. 
         [0037]    Multiple drill point screws  157  can then drill down through the metal roofing and MGO structural insulated panel assembly into steel supporting structure underneath, such as the vented C roof support  127  and the truss assembly  119 . 
         [0038]    Shown in the current embodiment is a door panel  104  that opens to the side on embodied overhead ball bearing rollers. A door header  137  can be utilized to complete the structural opening. 
         [0039]    Structurally connecting the side panels at the top can be a roof drill plate  130  into which the roof screws  157  can be drilled into and affixed to. 
         [0040]    The embodied building design can be airlifted, as an entire assembled structure, with some interior payload, up to an 8′&gt;12′ (or dash −03 configuration). The process can begin by removing the vent covers or exhaust plumbing from the side pick plates  129  and thread a 14′ schedule  40 , aluminum, 3½″ pipe, through the 2 holes. Then the pipe can be secured from sliding longitudinally, with a couple of hose clamps. Then a helicopter may lift the building to a remote location. Re-level the floor and use the building. 
         [0041]    In embodiments, a quick release pin with a combination or keyed lock can be used for securing the door from the outside. The quick release pin can be used to secure the door from the inside. 
         [0042]    In embodiments, extra thermal insulation may be added to the underside of the vaulted ceilings. The thickness of the extra insulation material can be up to 1½″ thick and still allow plenum room for a 36″ fan (not shown) surface mounted under the central C roof support  127 . 
         [0043]    The inner area  113  of the central C roof support channel(s) may be used as a combination space for vents, electrical cables, wires, water and gas piping, air ducting for HVAC purposes and insulation. 
         [0044]    All panel to panel abutting joints interior and exterior can be silicon caulked for weather sealing. Sliding doors are sealed with nylon brush seals on top and sides. Bottom seal is a commercially available threshold type seal. 
         [0045]      FIG. 2  depicts a sidewall panel  123  assembly (without window perforation) according to one or more embodiments. End wall assembly panels  125  can be similar, and in one embodiment design, the end wall panel has a slope and plateau upper edge section(s). 
         [0046]    In this embodiment, strut edge  209  and dual strut edges  210  are miter joint welded together on 3 sides. Then the inner layered glass reinforced MGO board  203  can be slide inserted from the open end with the thermal break screen  214 . Due to the fire resistant nature of the MGO board, then a top strut edge  209  can be welded in place, capturing MGO board  203 . This process is critical in creating an extremely fire resistant panel assembly. MGO cross studs  205  and MGO backer strips  207  can then be added with a paste like adhesive  215  to wedge MGO board  203  in place. At this construction point, additional adhesive  215  is spread on outer surfaces of MGO cross studs  205  and MGO backer strips  207  and the outer MGO board  204  is set in place, drilled and mechanically fastened together. Grind all miter joint welds flush. 
         [0047]    In one embodiment, stainless steel (SS) screws  218  can be inserted in the drilled holes from the outside, and tightened in place with a SS flanged nut  220 . 
         [0048]    Four drilled vent holes in the strut edge corners allow sealing inner and outer perimeter joints between MGO board and steel strut with adhesive  215 . Applying primer paint to all sides can finish the panel assembly  123 . Final paint coats can be applied after field assembly of the building. 
         [0049]    This described process can provide rugged edge protection of MGO boards from flaking and breakage, and provide strong fastening surfaces to adjacent panels and roof structures. 
         [0050]    Similar fabrication techniques are employed for the door and floor panel assemblies. 
         [0051]    Panel assemblies made in this manner are inherently resistant to shear forces or compressive forces parallel to the surface plains of the panels. 
         [0052]      FIG. 2A  depicts a vertical side section detail of a sidewall panel assembly  123  according to one or more embodiments. 
         [0053]    In this embodied detail, common, commercially available steel (or stainless steel) strut edge  209  and dual vertical strut edges  210  of the same material, are miter joint welded together on 3 sides. Then the inner glass reinforced MGO board  203  can be slide inserted from the open end with the thermal break screen  214 . Then due to the fire resistant nature of the MGO board, a top strut edge  209  (not shown) can be welded in place capturing the inner MGO board  203  and thermal break screen  214 . MGO board  203  cannot then be removed from within the strut edges at this point unless one breaks the board. MGO cross studs  205  and MGO backer strips can then be added on top of screen  214  with a paste like adhesive  215  to wedge MGO board  203  in place. Additional adhesive  215  can be spread on outer surfaces of MGO cross studs  205  and MGO backer strips  207  and the outer MGO board  204  is set in place, match drilled and fastened together. 
         [0054]    In one embodiment, stainless steel (SS) screws  218  can be inserted in the drilled holes from the outside, and tightened in place with a SS flanged nut  220 . 
         [0055]    This described process can provide inherent highly thermally insulated panels due to the inefficiencies of passing conducted heat through screen. Inserted screen  214  decreases heat transfer and can provide future spacing for sheets of Kevlar and/or steel (bullet resistant panel), Polyurethane (blast resistant panel), very fine wire cloth (electromagnetic resistant panel if properly grounded), and/or lead (radiation resistant panel). Other attractive properties can be achieved or enhanced with other inserted material embodiments. 
         [0056]    The air pockets shown can be partially filled with other insulative materials as desired, like Reflectix™ radiant barrier laminate roll. 
         [0057]    While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.