Field

[0001] The present invention generally relates to the field of prefabricated buildings, and in particular, to prefabricated modular homes, offices or other type of buildings.

Background

[0002] Prefabricated buildings are widely used as temporary homes, holiday accommodation, offices and other types of buildings. Prefabricated buildings are typically created as modular homes, offices or other types of buildings in a factory setting and then transported directly to site. If needed, the pre-fabricated buildings can be assembled on site. As of 2019, the prefabricated buildings represented 3% of Australian construction industry and are expected to reach 15% by 2025.

[0003] Prefabricated buildings are generally made by constructing portable buildings from scratch. Galvanised steel sheet panelling and a rigid insulation core are typically used to build prefabricated buildings. Such portable buildings are not cyclone rated and are difficult to lock down to the ground in cyclone areas. Furthermore, existing portable prefabricated buildings are not stackable and can be easily damaged due to the lightweight construction. Lifting such prefabricated portable buildings and placement onsite are not possible by a forklift and special crane lifting points need to be used making installation less cost efficient. Additionally, design life of existing portable buildings is on average less than 9 years which may not be long enough.

[0004] There have been attempts to use shipping containers at least as temporary buildings. However, such solutions are not portable and typically require on site constructions by placing two or more shipping containers side by side in perfect alignment on a levelled foundation, sealing any gaps between the containers and optionally removing internal side wall(s). Accordingly, such an approach requires two or more shipping containers and an on-site construction which is not cost efficient. Additionally, the comer posts of the shipping containers as well as potential relative movement and misalignment between two shipping containers complicates the provision of watertight sealing between two shipping containers, which is of particular concern for cyclone prone regions. [0005] One approach disassembles the roof, walls and floor of the shipping container and then re-assemble these parts in a new configuration to make a manually customised building. This approach is largely manual, expensive and not scalable to meet demands of growing industry.

[0006] Accordingly, there is a need to have pre-fabricated buildings which are cost-efficient, portable, durable, easily installed and manufactured.

Summary of Invention

[0007] It is an object of the present invention to substantially overcome, or at least ameliorate, one or more of the above disadvantages of existing arrangements, or provide a useful alternative.

[0008] According to one aspect of the present invention, there is provided a modified shipping container comprising: a pair of elongated sidewalls spaced apart by an elongated roof and an opposing elongated floor, the roof having parallel corrugations extending transverse to a longitudinal axis of the roof; wherein the roof has a first roof portion, a second roof portion and a widening panel extending longitudinally between the first roof portion and second roof portion such that the corrugations extend across the first roof portion and the second roof portion and align with and connect to the corrugations in the widening panel.

[0009] The first roof portion and the second roof portion may correspond to portions of a single shipping container cut lengthwise. The widening panel and the first roof portion may overlap. The widening panel and the second roof portion may overlap. Each corrugation in the first roof portion may be joined with or connected to the respective corrugations in the second roof portion and the widening panel by welding.

[00010] In some implementations, the modified shipping container also comprises a pair of end walls at opposing ends of the elongated sidewalls, the roof and the floor, wherein the elongated floor has a floor widening panel and the end walls have respective end wall widening panels.

The at least one end wall may comprise external edges connected to the pair of side walls, the roof and the floor and internal edges defining an opening, the opening extending from a first end wall portion to a second end wall portion across the end wall widening panel. The opening may be at least one of a window and a door. [00011] The modified shipping container may comprise four corner posts. The modified shipping container may further comprise at least one twistlock casting at each distal end of each corner post. The modified shipping container may comprise two twistlock castings at each distal end of each comer post.

[00012] In accordance with another aspect of the present invention, there is provided a method of modifying a shipping container having elongated sidewalls, an elongated roof, and an opposing floor, the roof having parallel corrugations extending transverse to a longitudinal axis of the roof, the method comprising: engaging the floor with a support jig and supporting the roof to prevent movement while the container is cut into two sub-containers; cutting the roof and the floor lengthwise using a cutting jig to form the two sub-containers, each sub-container having a roof portion, a floor portion and a respective one of the elongated sidewalls; displacing the sub containers apart using the support jig; positioning a widening panel to extend between the roof portion of one of the two sub-containers to the roof portion of the other of the two sub containers, the widening panel having corrugations that correspond with the parallel corrugations in each of the roof portions, the widening panel being positioned to align the parallel corrugations in the roof portions with the corrugations in the widening panel; and connecting the aligned corrugations in the roof portions and in the widening panel while holding the sub-containers using the support jig.

[00013] Engaging the floor may further comprise: fastening twist lock castings of the container to the support jig; supporting an underside of floor beams of the container; and welding at least two plates to the container and clamping the at least two plates to the support jig. The method may further comprise: centrally positioning the cutting jig with respect to the container; and sliding the cutting jig into the container along the elongated sidewalls to simultaneously cut the roof and the floor.

[00014] In accordance with a further aspect of the present invention, there is provided a portable modified shipping container, the shipping container comprising: an elongated roof having parallel corrugations extending transverse to a longitudinal axis of the roof; a floor opposing to the roof; and a pair of elongated sidewalls, the sidewalls being spaced apart by the roof and the floor, wherein the roof comprises a first roof portion and a second roof portion separate from each other and extending lengthwise along one of the elongated sidewalls, the first roof portion and the second roof portion being joined together such that corrugations in the first roof portion align with and connect to corrugations in the second roof portion.

[00015] In accordance with another aspect of the present invention, there is provided a system for supporting a shipping container for widening, the system comprising a support jig configured to support the shipping container, wherein the support jig comprises: a base portion configured to enable widening of the shipping container, a fixed supporting portion fixedly mounted on the base portion and extending lengthwise to support a first portion of the shipping container, a movable supporting portion substantially aligned with the fixed supporting portion and extending lengthwise to support a second portion of the shipping container different to the first portion, the movable supporting portion being slidably mounted on the base portion and configured to slide along the base portion with the second portion of the shipping container being secured to the movable supporting portion.

[00016] The system may further comprise a cutting jig comprising a support assembly, a frame slidably mounted on the support assembly, the frame being configured to slide into the shipping container and comprises at least one saw configured to cut at least one of the floor and the roof lengthwise while the frame is sliding. In some implementations, each of the fixed supporting portion and the movable supporting portion comprises at least one support beam to support floor beams of the shipping container lengthwise, wherein the at least one support beam be being vertically movable to adjust a vertical position of the at least one support beam such that the at least one support beam touches the floor beams of the shipping container.

[00017] The system may further comprise: a first fastening assembly at a distal end of the fixed supporting portion configured to secure the first portion of the shipping container to the fixed supporting portion; and a second fastening assembly at a distal end of the movable supporting portion configured to secure the second portion of the shipping container to the movable supporting portion so that the second portion is secured to the movable supporting portion while the movable supporting portion moves with respect to the first portion of the shipping container to enable widening of the shipping container. Each fastening assembly may be configured to engage a corresponding twist lock of the container.

[00018] The system may further comprise a roof supporting assembly simultaneously supporting the first portion of the shipping container and the second portion of the shipping container, wherein the roof supporting assembly is slidable inside the shipping container and is configured to have an adjustable height to support the first and second portions of the shipping container from inside.

[00019] Each supporting portion may comprise, at a proximal end, a screw adjustment assembly engaging an end beam of the shipping container to support the end beam from falling and a clamp assembly configured to prevent the shipping container from lifting when the shipping container is cut. The movable supporting portion may be configured to slide with preset stops determined by a desired width for widening.

[00020] Other aspects are also disclosed.

Brief Description of Drawings

[00021] A range of suitable embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non-limiting embodiment, described in connection with the accompanying drawings. In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.

[00022] Fig. 1 shows left side/front perspective view of a modified shipping container 100 in accordance with one implementation of the present disclosure.

[00023] Figs. 2 depicts a left side/rear perspective view of the modified shipping container 100. [00024] Fig. 3 is a right side/front perspective view of the modified shipping container 100. [00025] Fig. 4 is a right side/rear perspective view of the modified shipping container 100. [00026] Fig. 5 shows a front elevation view of the modified shipping container 100. [00027] Fig. 6 is a side elevation view 600 of the modified shipping container 100.

[00028] Fig. 7 shows a section view of a modified shipping container through a plane parallel to one of the elongate side walls.

[00029] Fig. 8 shows a transverse section view of a modified shipping container through a plane parallel to an end wall.

[00030] Fig. 9 shows two modified shipping containers stacked on top of each other.

[00031] Figs 10, 11 and 12 demonstrate examples of transportation of the modified shipping container.

[00032] Fig. 13 is a front elevation view of a modified shipping container in accordance with one implementation of the present disclosure.

[00033] Fig. 14 shows a side elevation view of the modified shipping container of Fig. 13. [00034] Fig. 15A demonstrate a section of corrugated sheet metal used in shipping containers. [00035] Fig. 15B is an enlarged view of a twist lock casting.

[00036] Figs. 16A and 16B show a support jig in an initial configuration and in an extended configuration respectively in accordance with one implementation of the present disclosure.

[00037] Figs. 17 and 18 are right/top perspective views of the support jig in the initial and extended configurations respectively.

[00038] Figs. 19 and 20 demonstrate left/top perspective views of the support jig in the initial and extended configurations respectively.

[00039] Figs. 21 and 22 are plan views of the support jig in the initial and extended configurations respectively.

[00040] Fig. 23 A shows a standard shipping container to be extended in accordance with an implementation of the present disclosure. [00041] Fig. 23B shows an example roof support assembly.

[00042] Fig. 24A demonstrates an example of the support jig.

[00043] Fig. 24B is an example of a cutting jig in a parked configuration.

[00044] Fig. 25 A shows the example cutting jig ready for use.

[00045] Fig. 25B shows the unmodified shipping container placed on the support jig.

[00046] Fig. 25C shows an example of a screw adjustment assembly and a clamp assembly.

[00047] Fig. 26A shows an example of support beams of the support jig of Fig. 24A.

[00048] Fig. 26B shows the support jig of Fig. 24A in an extended configuration with the shipping container cut longitudinally into two spaced apart sub-containers.

[00049] Fig. 26C an example of an optional roof jig configured to operate with the support jig of Fig. 24A.

[00050] Fig. 27A shows the roof support assembly inside an original shipping container cut into two sub-containers.

[00051] Fig. 27B shows a widened modified shipping container in accordance with one implementation of the present disclosure.

[00052] Fig. 28 is a flowchart of a process of widening an original shipping container in accordance with one implementation of the present disclosure.

[00053] Figs. 29A to 29D shows different section view of relative arrangement of internal and external twist lock castings.

[00054] Fig. 30A-F show example implementation details of additional roof and floor beams.

[00055] Fig. 31A shows roof sheeting. [00056] Figs. 3 IB and 31C depict example wall sheeting to wall sheeting and wall sheeting to corners port arrangements.

Description of Embodiments

[00057] The present disclosure relates to modified shipping containers which can be used as an inhabitable space, including offices, ablution units, lunchrooms, cafes, bars, accommodation units etc. A shipping container can be widened in accordance with the present disclosure so that the shipping container becomes wide enough to use effectively as an office, accommodation, cafes, bars etc (also referred to as “a modified shipping container”). Additionally, the modified shipping container may re-use twist locks of typical shipping containers for safer transport, which is particularly important for larger modified widened shipping containers. The modified shipping container may have inbuilt fork pockets and inbuilt lifting points. The twist locks can also be used to lock the modified widened shipping container down to ground for cyclone areas.

[00058] For the purposes of this disclosure, the term “shipping container” refers to a shipping container, for example, in accordance with the ISO 668 standard. The major advantages of using shipping containers over other types of prefabricated modular buildings are listed below.

• Strength and durability: shipping containers are constructed of steel and designed to carry loads upwards of 27,000kg depending on the size and longer containers can weigh over 4,500kg at their tare weight. Because of the rugged construction and structural strength, shipping containers are virtually hurricane-proof and earthquake-proof. The weathering steel that shipping containers are made of creates a regenerative protective layer when it oxidizes that prevents it from further corrosion to withstand the elements.

• Mobility: Because the shipping containers are intended to be able to ship virtually anywhere, the shipping containers can easily be transported by ship, truck or rail and are ideal for transport. When used as building blocks the shipping containers can be stacked, i.e. the building can eventually be disassembled, relocated and erected again should the need arise.

Affordability: Depending on location and availability, shipping containers can be purchased and delivered for a relatively low price. All modifications to shipping containers, such as electrical, interior finishes, plumbing and insulation can mostly be done at the manufacturing site.

[00059] Despite the advantages listed above, shipping containers tend to be widely used as storage solutions and not as inhabitable buildings due to narrow width and lack of solutions for configuring shipping containers as inhabitable buildings in a cost-efficient, easily installed and manufactured manner. The main disadvantage is that the standard shipping containers are quite narrow. For example, shipping containers come in standard sizes of approximately 2.4 metres wide and lengths of 6 metres or 12 metres. Insulation of a shipping container to be liveable through summers and winters further reduces the useful area available making a single shipping container too narrow and a double, joined in the middle, too wide and expensive to get a really efficient layout.

[00060] To facilitate adoption of shipping containers as inhabitable buildings, the present disclosure proposes modifying a standard shipping container. The modified shipping container is typically wider than the standard shipping container, however, the modified shipping container can also be narrower than the standard shipping container without loss of generality.

In a preferred implementation, the modified shipping container is a widened shipping container. The modified widened shipping container is formed by cutting one or more shipping containers lengthwise to form two sub-containers, inserting a roof widening panel between the two sub containers to widen the shipping container and joining the roof widening panel and the two sub containers.

[00061] The width of the widening panel is chosen to increase the overall width of a standard shipping container. In some implementations, the width of the widening panel does not exceed 1050mm so that the modified widened shipping container stays below the maximum width of 3.5m to be able to be transported by road as a load without a permit or an escort. Accordingly, the width of the widening panel may be anywhere between 1mm and 1050mm. In practice, the width of the widening panel may be 550mm or 1050mm so that a final width of the modified shipping container is 3m or 3.5m to be able to be transported by road. However, different dimensions of the widening panel are also possible. If even wider modified shipping container is required, two shipping containers can be used instead. For example, each container can be cut open lengthwise to remove a sidewall together with comer posts thus forming “sub-containers”. The sub-containers can then be joined together as discussed above. [00062] Consequently, if a narrower container is required, there is no need to have a widening panel, i.e. two sub -containers can be joined together directly without a widening panel. It should be noted that the width of at least one sub-container would be smaller than half the width of the standard shipping container if a narrower modified shipping container is required.

[00063] Fig. 1 shows left side perspective view of a modified shipping container 100 in accordance with one implementation of the present disclosure. Figs. 2, 3 and 4 show rear left side perspective view 200, right side perspective view 300 and rear right side perspective view 400 of the modified container 100 respectively.

[00064] The modified shipping container 100 comprises a pair of elongated sidewalls 105 and 205 spaced apart by an elongated roof 107 and an opposing elongated floor (not shown). The roof 107 has parallel corrugations 115 extending transverse to a longitudinal axis of the roof 107. The roof 107 has a first roof portion 110, a second roof portion 120 and a widening panel 130. The first roof portion 110 and the second roof portion 120 correspond to portions of a single shipping container 100 cut lengthwise.

[00065] The widening panel 130 extends longitudinally between the first roof portion 110 and second roof portion 120 such that the corrugations 115 extend across the first roof portion and the second roof portion (corrugations 125) and align with and connect to the corrugations 135 in the widening panel.

[00066] The modified shipping container 100 also comprises a pair of end walls 137 and 310 at opposing ends of the elongated sidewalls 105 and 205, the roof 107 and the floor. The elongated floor may have a floor widening panel as shown in Fig. 27B and the end walls have respective end wall widening panels 640 as shown in Fig 6. Example wall sheeting of the end wall widening panel to the remaining end wall is shown in Fig. 3 IB with 25mm overlap. Wall sheeting to a corner post is shown in Fig. 31C. At least one end wall 137 comprises external edges 138 connected to the pair of side walls 105 and 205, the roof 105 and the floor. The end wall 137 may also include internal edges 155 defining an opening 157, the opening may extend from a first end wall portion to the second end wall portion across the end wall widening panel. The opening 157 is at least one of a window and a door.

[00067] The widening panel 130 and the first roof portion 110 may overlap, for example, as shown in Fig. 31 A with 50 mm overlap. The widening panel 130 and the second roof portion 120 may also overlap. In some implementations, each corrugation in the first roof portion 110 is joined with, or connected to, the respective corrugations 125 in the second roof portion 120 and corrugations 135 of the widening panel 130 by welding.

[00068] The modified shipping container 100 may comprise at most 4 comer posts 140. For example, two comer posts from each sub -container. At least one twistlock casting 145 is positioned at each distal end of each comer post. In some implementations two twistlock castings 143 and 145 are located at each distal end of each corner post. The modified shipping container 100 may also have an additional twistlock casting at another end of the corner post 140 proximal to the roof 107.

[00069] The internal (additional) twist lock casting 143 can be placed about 45mm lower than the external (original) twist lock casting 145, for example, as shown in Figs. 29A to 29D. Positioning of the internal twist lock castings 143 lower than the external twist lock castings 145 allows transportation of the widened container 100 on a tilt tray type truck, for example as shown in Fig. 10, while using existing transport locks of the tilt tray type truck for the safe transport of the widened container. Since an edge of a tilt tray edge beam 1010 is about 45mm above a tray deck 1020 and the internal twist lock castings 143 are about 45 mm lower than the external twist lock castings 145, twist locks can slide within the internal twist lock casting 143 upon the edge of the tilt tray edge beam 1010 to lock the modified shipping container 100 down to the deck 1020 for transport.

[00070] Fig. 5 shows a front elevation view 500 of the modified shipping container 100. The modified shipping container 100 has a corrugated roof 510, a door opening 511 having a width extending from 512 to 514 and a height 516. The modified container 100 also comprises a window opening 520 having a width extending from 522 to 524 and a height extending from 528 to 526. The container 100 also comprises twist lock castings 530 and 535 and fork lift tyne pockets 540. The fork lift tyne pockets 540 are configured to receive fork tynes sliding into the pockets 540 to pick up the modified shipping container 100.

[00071] Fig. 6 demonstrate a side elevation view 600 of the modified shipping container 100. The modified shipping container 100 comprises an end wall 605, a comer post 610 with twist lock castings at a proximal (top) end and a distal (bottom) end of the comer post 610 with respect to the roof. One twist lock casting 615 may be fitted at the proximal end of the comer post 610 and a pair of twist lock castings may be fitted at the bottom of the distal end of the corner post 610. The pair of twist lock castings comprises an internal twist lock casting 630 and an external twist lock casting 620. The end wall 605 comprises an end wall widening corrugated panel 640. The end wall widening corrugated panel preferably has corrugations corresponding to the corrugations in the remaining sections of the end wall 605.

[00072] Fig. 7 shows a section view of the modified shipping container 100 along the elongated side wall. The modified shipping container 100 may comprise a window 710 extending horizontally from 712 to 714 and extending vertically from 716 to 718 and an air conditioner box mount 750. The modified shipping container may also comprise additional roof support beams 720 and 722 extending transversely with respect to the elongate roof 107 and in parallel to the corrugations 115, 125 and 125. The modified shipping container 100 may also comprise corner double plates (or gussets) 730 and 760 to carry the load from the corner twist locks to the transport locks when the modified shipping containers 100 are stacked one on the other, as the modified shipping containers 100 are stacked using the external (or corner) twist locks. The corner gussets can be made in different manners, for example, the corner gussets 760 may be square instead of triangular.

[00073] The modified shipping container 100 may also comprise additional main roof beams within 705L, 705R and additional main floor beams within 740L and 740R for joining to the end walls. Enlarged views of the sections 740L, 740R, 705L and 705R are shown in Figs. 30A,

30B, 30C and 30D respectively.

[00074] The additional main beams are configured to support the roof and floor widening panels and improve rigidity of the overall modified shipping container 100. Each of the additional main beams within 705L, 705R, 740L and 740R is made from a sheet of steel folded into a required shape. The shape of the additional main beams depends on the shape of the beams of the original shipping container. Example shapes of the additional main floor beams are shown as MK.13/D and MK.13/H for left and right main additional floor beams respectively.

MK.l 1/H is used to align and support the internal twist lock castings 910 (also referred to as transport locks) as well as for welding the internal twist lock castings 910 to the rest of the modified shipping container 100. Example shapes of the additional main roof beams are shown as MK.13/B welded together with MK.13/C for the left main additional roof beam and MK.13/F for the right main additional roof beam respectively. [00075] Fig. 8 depicts a transverse section view of the modified shipping container 100 along the end wall 810 having an extension panel 820 and an air conditioner box mount 850 having dimensions 852, 854, 856 and 858. The modified shipping container 100 may also have various style end beams 830 depending on the container, and roof support beams 840. The end beams 830 and the roof support beams 840 can be positioned parallel to the corrugations 115, 125 and 135 in the roof 107. The beams 830 and 840 may be made in a similar manner as existing beams of the original shipping container.

[00076] The modified shipping container 100 may have corner gussets 860 positioned in the vicinity of the twist lock castings to support the transport locks, fork lift tyne pockets 870 and additional floor beams 880. The fork lift tyne pockets may be strengthened as shown in Fig. 30E, e.g. MK.11/G and MK.11H, across the entire width of the modified shipping container 100 to enable transportation by a fork lift.

[00077] The additional floor beams 880 may be a form of a C-channel as shown as MK.13/A in Figs. 30A and 30B. The additional floor beams 880 extend across the width of the widening panel 130. The additional floor beams 880 may be joined with the original floor beams in different manners. For example, the additional and original floor beams may overlap as shown in Fig. 30E and welded together. Alternatively, the additional and original floor beams may be joined using butt joins or by fitting the additional floor beams within the original floor beams.

[00078] Fig. 13 shows another front elevation view 1300 of the modified shipping container 100 along an elongate side wall. As discussed above, the modified shipping container may have a corrugated roof 1305 with transverse corrugations 1310. Fig. 15A shows a corrugated profile of a section 1500 of a corrugated roof and/or widening panel 1510 in accordance with one implantation of the present disclosure. The corrugations may have a period of 209 mm and a height of 24 mm.

[00079] The modified shipping container may also comprise a floor beam 1320 and comer posts with twist lock castings 1340 and 1350.

[00080] A side elevation view 1400 of the container 100 is shown in Fig. 14. The side elevation view shows internal twist lock castings 1410, an end wall extension panel 1420 and external twist lock castings 1340. Fig. 15B shows an enlarged front view of a twist lock casting 1410 in accordance with one implementation. [00081] The modified shipping container 100 is generally made by cutting a single shipping container lengthwise into two sub-containers while also stabilizing the shipping container from collapsing when being cut and joined together. A method 2800 of modifying the shipping container in accordance with one implementation of the present invention is shown in Fig. 28 and explained below with references to Figs. 23 A to 27B.

[00082] The method 2800 of modifying a shipping container starts by placing the original shipping container 2300 having elongated sidewalls 105 and 205, an elongated roof 107, and an opposing floor on a support jig 2400. Details of the support jig 2400 are provided below with references to Figs. 16 to 22 and 24A, 25B, 25C, 26 A and 26B. The roof of the shipping container 2300 has parallel corrugations extending transverse to a longitudinal axis of the roof.

[00083] After the shipping container 2300 is placed on the support jig 2400, the method 2800 proceeds to engaging the floor and the roof to prevent movement while the original shipping container is cut into two sub-containers. Once the floor and the roof are engaged, the method 2800 proceeds to cutting 2820 the roof and the floor lengthwise using a cutting jig 2450 to form the two sub-containers, each sub-container having a roof portion, a floor portion and a respective one of the elongated sidewalls. Structural features of the cutting jig 2450 are described below with references to Figs. 24B, 25 A and 26C.

[00084] Step 2820 proceeds to step 2830 of displacing the sub-containers apart using the support jig 2400. When the sub-containers are displaced, the method 2800 proceeds to positioning 2840 a widening panel 130 to extend between the roof portion of one of the two sub containers to the roof portion of the other of the two sub -containers. The widening panel 130 has corrugations that correspond with the parallel corrugations in each of the roof portions. The widening panel 130 is positioned to align the parallel corrugations 115, 125 in the roof portions with the corrugations 135 in the widening panel 130.

[00085] Step 2840 of the method 2800 continues to connecting 2850 the aligned corrugations 115, 125, and 135 in the roof portions and in the widening panel 130 while holding the sub containers using the support jig 2400. Once the aligned corrugations 115, 125 and 135 are connected, the modified shipping container is ready for use. The method 2800 concludes.

[00086] A portable shipping container in accordance with another implementation of the present disclosure comprises an elongated roof having parallel corrugations extending transverse to a longitudinal axis of the roof, a floor opposing to the roof and a pair of elongated sidewalls spaced apart by the roof and the floor. The roof, floor and the sidewalls can be similar to those described above.

[00087] The roof may comprise a first roof portion and a second roof portion separate from each other and extending lengthwise along one of the elongated sidewalls. The first roof portion and the second roof portion can be joined together such that corrugations in the first roof portion align with and connect to corrugations in the second roof portion.

[00088] Structural features supporting integrity of the shipping container and preventing the shipping container from collapsing while being cut are disclosed below with references to Figs. 16A to 26C. In one implementation, a system for lengthwise supporting a shipping container is used. The system for lengthwise supporting the shipping container is typically used for widening, however, can also be used to make narrower container.

[00089] The system comprises a support jig 1600 configured to support the shipping container. Fig. 16A shows side view of the support jig 1600 in an initial or starting configuration. Fig.

16B shows the support jig 1600 is an extended configuration 1650. Figs. 17 and 18 depict right perspective views 1700 and 1800 of the support jig 1600 in the original configuration and in the extended configuration 1650 respectively. Figs 19 and 20 are a left perspective views 1900 and 2000 of the support jig in the initial configuration and in the extended configuration 1650 respectively. Figs. 21 and 22 are top views 2100 and 2200 of the support jig 1600 in the initial and the extended configurations respectively.

[00090] The support jig 1600 comprises abase portion 1610, a fixed supporting portion 1620 and a movable supporting portion 1630. The base portion 1610 is configured to enable widening of the shipping container 2300. For example, the dimensions of the base portion 1610 allow widening of the shipping container 2300 by up to 1050mm on the support jig 1600. Various additional widths can be obtained by using a wider support jig. Additionally, the base portion 1610 can be configured to support the fixed supporting portion 1620 and the movable supporting portion 1630. The fixed supporting portion 1620 can be integrally formed with the base portion 1610.

[00091] The fixed supporting portion 1620 is fixedly mounted on the base portion 1610 and extends lengthwise to support a first portion of the shipping container 2300. The fixed supporting portion may be dimensioned to support a first sub-container along substantially the entire width and length of the first sub-container, for example, as shown in Figs. 25B and 26B.

[00092] The movable supporting portion 1630 substantially aligns with the fixed supporting portion 1620 and is similarly dimensioned. The movable supporting portion 1630 extends lengthwise to support a second portion of the shipping container different to the first portion, for examples as shown in Figs. 25B and 26B. For example, the movable supporting portion 1630 may be dimensioned to support a second sub-container along substantially the entire length of the second sub-container as shown in Fig. 26B. The movable supporting portion 1630 is slidably mounted on the base portion 1610 and is configured to slide along the base portion with the second portion of the shipping container 2300 being secured to the movable supporting portion 1630. For example, the second sub-container can slide together with the movable supporting portion 1630 while the movable supporting portion 1630 is sliding along the base portion. The movable supporting portion 1630 is configured to slide with preset stops determined by a desired width for widening. For example, the movable portion 1630 can slide in a new position as shown in the extended arrangement 1650 in Fig. 16B.

[00093] Each of the fixed supporting portion 1620 and the movable supporting portion 1630 may comprise at least one support beam 1710, 1720 and/or 1730 to support floor beams of the shipping container 2300 lengthwise. The at least one support beam can be vertically movable to adjust a vertical position of the at least one support beam such that the at least one support beam touches the floor beams of the shipping container 2300.

[00094] Additionally, each supporting portion 1620, 1630 may comprise, at a proximal end, a screw adjustment assembly engaging an end beam of the shipping container to support the end beam from falling. Each supporting portion may also comprise a clamp assembly configured to clamp to a corresponding welded panel of the shipping container to prevent the shipping container from lifting when the shipping container 2300 is cut.

[00095] Additionally, the system may also comprise a first fastening assembly 1910 at a distal end of the fixed supporting portion 1620. The first fastening assembly 1940 may be configured to secure the first portion of the shipping container 2300 to the fixed supporting portion 1620. The system may also comprise a second fastening assembly 1740 at a distal end of the movable supporting portion 1630. The second fastening assembly 1740 is configured to secure the second portion of the shipping container 2300 to the movable supporting portion 1630 so that the second portion is secured to the movable supporting portion 1630 while the movable supporting portion 1630 moves with respect to the first portion of the shipping container 2300. Securing the first and second portions of the shipping container 2300 on respective supporting portions 1620 and 1630 enables portions of the shipping container 2300 to be pulled apart while maintaining alignment thereby enabling precise widening of the shipping container 2300. Each fastening assembly 1740, 1910 may be configured to engage a corresponding twist lock of the shipping container 2300.

[00096] In some implementations, the system also comprises a roof supporting assembly, for example, 2350 as shown in Fig. 23B. The roof supporting assembly 2350 simultaneously supports the first portion of the shipping container 2300 and the second portion of the shipping container 2300. The roof supporting assembly 2350 may be slidable inside the shipping container 2300. Additionally, the roof supporting assembly 2350 may be configured to have an adjustable height to support the first and second portions of the shipping container 2300 from inside.

[00097] The system may also comprise a cutting jig, for example, 2450 as shown in Fig. 24B. The cutting jig 2450 comprises a support assembly 2460 and a frame 2470 slidably mounted on the support assembly 2460. The frame 2450 is configured to slide into the shipping container 2300. The frame 2450 comprises at least one saw configured to cut at least one of the floor and the roof lengthwise while the frame 2470 is sliding. In a preferred implementation, the frame 2470 comprises three adjustable saws 2510, 2520 and 2530 shown in Fig. 25A.

[00098] A first saw 2520 is configured to cut the roof and is height-adjustable, a second saw 2530 is configured to cut the floor and the third saw 2510 is cutting configured to cut the end wall. All saws 2510, 2520 and 2530 can be remotely controlled. For example, the operating height of the first 2520 and the second 2530 saws can be set and fixed remotely such that the first and second saws are able to cut the floor and the roof lengthwise while the frame is sliding. The third saw 2510 is remotely controlled to make a vertical cut of the end wall when the frame reaches the end wall. For example, the third saw 2510 is remotely controlled to cut the end wall when the frame 2470 reaches the end wall. The third saw 2510 may start cutting from a bottom end portion of the end wall adjacent to the floor and progress vertically towards the roof. [00099] To fabricate a portable building from a widened shipping container, any sized shipping container may be used depending on the design of the finished product. Common shipping container sizes are 6m x 2.4m and 12m x 2.4m. Shipping containers typically come in standard height [8’6”] or High cube [9’6”]. The present disclosure is not limited to specific dimensions of a shipping container and is able to modify shipping containers having different dimensions.

[000100] In accordance with one implementation, the shipping container is widened using a purpose-built jig, cutting the container longways down the centre line and pulling the two sections or “sub-containers” apart to any width that is required. For example, to width 3.0m or 3.5m and up to any width can be accommodated.

[000101] Fig. 23A shows a typical standard height 6m x 2.4m shipping container 2300 also referred to as “an original shipping container”. The term “original shipping container” refers to a shipping container which is to be modified, e.g. widened or narrowed, i.e. input shipping container. The below description provides example implementation details of a process of widening the shipping container 2300 to a 6m x 3m modified shipping container. The modified 6m x 3m shipping container is suitable for use as a portable building for any purpose including, but are not limited to, cafes, bars, office, lunchroom, meeting room, workshop, accommodation buildings and the like.

[000102] Before cutting, front doors 2310, e.g. front end wall, of the original shipping container 2300 are removed by cutting through hinge pins. The removed doors are stored for later use.

[000103] The roof of the original shipping container is propped as shown in Fig. 23B using a roof supporting assembly 2350. The roof supporting assembly 2350 can be a purpose built propping system to support the roof sheeting while the container 2300 is being cut and when the widening panel 130 is welded to the first and second roof portions.

[000104] Fig. 23B shows the process of propping the roof of the original 6m x 2.4m shipping container 2300. The props 2360 and 2370 on the left are pushed against the elongate side wall 2375 of the original shipping container 2300 to allow room for a sliding mechanism which holds remote-controlled saws 2510, 2520 and 2530 for splitting the original shipping container 2300 (discussed below). The props 2360 and 2370 are screwed up gently until a support beam 2380 touches the roof sheeting and is not forced further. [000105] The support beam 2380 is intended to equally touch the roof sheet of the original shipping container 2300 for a length of the shipping container 2300. In some implementations, it may be also preferred for the support beam 2380 to touch only rippled roof sheeting and not the flat sheets on either end. Once the support beam 2380 substantially equally touches the roof sheet of the original shipping container 2300 substantially for the entire length of the original shipping container 2300, the props 2360 and 2370 are considered to be in place.

[000106] The original shipping container 2300 can be propped before or after the original shipping container 2300 is placed on a support jig 2400. If the original shipping container 2300 is propped before placing of the support jig 2400, the propped original shipping container is transferred to the support jig 2400 for further preparation and cutting.

[000107] Fig. 24A shows the support jig 2400 in more detail. The support jig 2400 comprises a base 2410 (similar to 1610), a fixed portion 2420 (similar to 1620) which is configured to remain in place and a sliding portion 2430 (similar to 1630) which is configured to move a half of the original shipping container 2300 away from a fixed half of the original shipping container 2300, once the original shipping container 2300 is cut.

[000108] Fig. 25B shows the support jig 2400 in a starting position 2550 with the original shipping container 2300 placed on the support jig 2400. The support jig 2400 has the same width as the original shipping container 2300, i.e. 2.4m, in the starting position. The original shipping container 2300 sits on the support jig 2400 secured with respect to the support jig 2400 so that the original shipping container 2300 is supported by the support jig 2400 at every point before proceeding with cutting.

[000109] The support jig 2400 may have a number of adjustment points to support the roof sheets, the floor beams, the end beams top and bottom to ensure that no part of the original shipping container drops downward while being cut. There are also pads to clamp the two halves of the container 2300 down to stop it lifting and ensures that neither half moves during this process.

[000110] The cutting jig 2450 comprises a support assembly2460 and a frame 2470 slidably mounted on the support assembly 2460. The frame 2470 has one or more steel cutting saws configured to cut metal of the original shipping container 2300. In one implementation, the frame 2470 comprises three remote controlled steel cutting saws 2510, 2520 and 2530 mounted on tracks. The frame 2470 is configured to slide into the propped original shipping container 2300 until the frame 2470 reaches a rear end wall of the original shipping container 2300.

[000111] To enable the centre line cut of the original shipping container 2300, the saws 2510, 2520 and 2530 are centrally aligned with respect to the original shipping container 2300. Two self-tapping screws in tabs provided may be used to fix the frame 2470 in position in the original shipping container 2300.

[000112] Fig. 24B shows the cutting jig 2450 in the outer position, parked waiting for the original shipping container 2300, whether propped or not, to be placed on the support jig 2400.

[000113] Fig. 25A shows the saws 2510, 2520 and 2530 attached to the track guides ready to have the protection covers attached. The saws 2510, 2520 and 2530 are configured to travel by remote control the length and height of the original shipping container 2300, making a complete cut through the original container 2300.

[000114] Once the roof of the original shipping container 2300 is propped, an overhead crane may be used to place 2550 the propped original shipping container onto the support jig 2400 as shown in Fig. 25B. In one implementation, the propped original shipping container is locked into place on the support jig 2400 with a fastening assembly, for example, using corner twist locks 2560 as shown in Fig. 25B.

[000115] A screw adjustment assembly 2570, for example, adjustment bolts [D] 2575, are screwed upward until the adjustment bolts 2575 touch end beams of the original shipping container 2300. By touching the end beams of the original shipping container 2300, the adjustment bolts 2575 will support the end beams from dropping when cut.

[000116] A plate 2580 may be welded to the original shipping 2300 to engage with a clamp assembly 2585. The clamp assembly 2585 may clamp the weld plate 2580 [E] to tabs on the support jig 2400 as shown in Fig. 25C, to stop portions of the original shipping container lifting once cut.

[000117] Fog. 26 A shows support beams 2610 [F] and 2615 [G] on the underside of the support jig 2400. The support beams 2610 and 2615 are used to support the floor beams of the original shipping container 2300 so they do not drop down while cutting and reinstating the floor. Jacks 2620 may be used to lift each support beam 2610 and 2615 to touch the floor beams along substantially the full length of the original shipping container 2300. Jacking is applied until the support beam just touches, no force needs to be applied to the floor beams by jacking. Forcing the jacks may jam the saw during the cutting process.

[000118] Once the original shipping container 2300 is fully propped and locked down to the support jig 2400, the original shipping container 2300 is then cut using the remotely controlled saws 2510, 2520 and 2530. The remotely controlled saws 2510, 2520 and 2530 may be configured to simultaneously cut the floor and the roof. The end wall may be cut last. In alternative implementations, only one saw may be used. If only one saw is used, the floor, the roof and the end wall may be cut sequentially in any order.

[000119] The original shipping container 2300 may be cut through the centre for the length of the original shipping container. In alternative implementations, the original shipping container 2300 may be cut off the centre and/or in any other manner which is deemed to be appropriate. For example, the original shipping container may be cut in a straight line, a curved line, a slope line, diagonally, zigzag etc. In one implementation, the floor and the roof of the original shipping container 2300 are cut in the same manner. In alternative implementations, the floor and the roof may be cut in different manners.

[000120] Once the cut is complete, i.e. the original shipping container 2300 is cut into two portions or “sub-containers”, the cutting jig slides out of the shipping container and placed into the park position.

[000121] The portion, e.g. a half, of the cut shipping container that is sitting on the moveable supporting portion 2430 of the support jig 2400 moves away from the fixed supporting portion 2420 [A] of the support jig 2400. Stops of the moveable supporting portion 2430 can be pre-set at a desired width on the support jig 2400 so that the portion of the shipping container 2400 stops automatically at the predetermined width.

[000122] With the shipping container 2300 in a new cut position, a roof jig [H] 2660 may be installed above the separated shipping container as shown in Fig. 26C. The roof jig 2660 may provide access to the roof area and walkways to assist in the assembly of the container roof and the end beams. Separate access to the roof jig 2660 is provided by a stairwell at the rear of the support jig 2400. [000123] With the roof jig 2660 in place and the cutting jig 2450 in its removed position, the cut shipping container is ready to be re-assembled into a modified widened shipping container. To make the modified widened shipping container, the widening panel 130 is placed on the spaced apart roof portions so that the transverse corrugations in the roof portions align with the transverse corrugations in each of the roof portions. When the transverse corrugations are aligned as discussed, each corrugation in a first roof portion is effectively extending all the way toward a distal end of a second roof portion through the widening panel as shown, for example, in Figs, 1 to 4, Fig. 27B. The widening panel is then welded to the first and second roof portions.

[000124] In a preferred implementation, a verification process is performed prior to welding the widening panel and the portions of the cut container. For example, all cut areas may be inspected and checked for alignment. All cut pieces may be are ground off removing burrs and sharp edges and prepared ready for welding.

[000125] The gaps in the floor, the end wall and the roof are filled in using widening panels and welded out. Braces, gussets and fork tyne pockets may be also installed.

[000126] Additional internal transport twist locks 143 may be installed, allowing the container to be transported by a tilt tray (for 6m containers).

[000127] The removed door at the end wall is welded in and the modified shipping container is now ready to be fitted out as a portable building. A clip in a walkway may be optionally attached to top widened shipping container for access when buildings are stacked

[000128] The above support jig 2400 holds the original and split shipping container together while the original shipping container is being cut and extended to a 3.0m widening position.

The support structures also hold the roof, side walls and floor together and steady so the original shipping container does not fall apart once is cut or being cut in half, for example. The disclosed cutting jig 2450 is configured to ensure the original shipping container 2300 is cut in a predetermined manner, i.e. in a straight line in this case. The additional four internal bottom twist lock castings 143 are added to the bottom of the modified shipping container, so the modified widened shipping container can be transported and stacked on top of each other. [000129] The above disclosure allows widening the standard shipping container from 2.4m to 3.0m or more in an efficient and cost-effective way and keeping the benefits of a shipping container, such as strength, durability, mobility and affordability, while making the modified shipping container more human scaled and consequently more comfortable. The proposed cutting process allows widening of the original shipping container while maintaining structural rigidity of the original shipping container while being cut. Welding is preferably done using extra side and roof weathering steel panels and extra flooring consistent with materials typically used for shipping containers. The steel panels are preferably made of 250 grade steel or higher, for example, according to the AS 3678, AS 3679 or AS 1163.

[000130] Widening the original shipping container as discussed above, for example from 2.4 to 3m, creates a new and improved modular building product and is facilitated by a new manufacturing process thus making a multi-use structure with an increased size from an otherwise too narrow building. Although the above disclosure is made with references to the standard shipping container according to the ISO 668 and ISO 6346 standard, the disclosed arrangements are also applicable for shipping containers of different sizes.

[000131] For example, for a High shipping container of the ISO 668 and ISO 6346 standard, height of the props of the roof supporting may be adjusted to the height of the High shipping container. Positioning of the saws of the cutting jig can be also adjusted to the height of the High shipping container.

[000132] If the shipping container has a different width than the width specified in the ISO 668 and ISO 6346 standard, the width of each of the fixed supporting portion and the moveable supporting portion may be adjusted. In alternative implementations, the moveable supporting portion may be moved further away from the fixed supporting portion in the initial configuration so that the shipping container is secured to the support jig as described above.

[000133] The disclosed arrangements provide several advantages. For example, the modified widened shipping container may be used for purposes that are not available to a standard 2.4m container due to the narrow width of the standard shipping containers. The modified widened shipping containers as discussed above are built by cutting a standard container longways and optionally adding in structural support to width wider than 2.4m. Typically, are modified shipping containers in accordance with the present disclosure are 3m and 3.5m wide but may be built to any wider design. Widening of a standard shipping container opens up multi-use opportunities as opposed to a standard shipping container typically used only for storage and/or shipping.

[000134] The modified widened shipping container can be safely transported using twist locks as shown in Figs. 10 to 12. Additionally, the modified widened shipping containers may serve as a basis for cyclone rated building with design life of about 25 years since the cyclone rated structures of the original shipping containers are used and are substantially intact. The modified widened shipping containers are easy installed by both lifting and locking down to the ground. The modified widened shipping containers are also stackable for use as two storey office or temporary accommodation, as shown in Fig. 9.

Examples of specific features of the modified container

[000135] The modified container 100 may be a 20 foot container with external dimensions 6060 mm x 3040 mm x 2350 mm high. The modified container 100 may be configured to have four external standard twist lock castings 920 at both roof and floor level for stacking, lifting and tie down. The modified container 100 may also have four internal twist lock castings 910 at floor level for transport and tie down. The external twist lock castings 920 are located at the external dimensions of the modified container; the four internal twist lock castings 910 are located at the standard 20 foot container dimensions to allow for transport.

[000136] The modified container 100 may have standard general use loading of 3.0 kpa. The modified container 100 is suitable for general use floor loading.

[000137] The modified container 100, whether standalone or stacked, can be positively fixed to anchor footings suitable for the wind loading of the site in which the office is located. The anchor footings can be designed by taking into account the wind and seismic loading conditions and the planned stacking configuration. Positive connection of the modified container 100 to the anchor footings may be achieved by the installation of embedded twist lock connectors into the anchor footings and connection of the modified container 100 to those twist lock connections. Embedment of the twist lock connections are configured to engage the anchor footings. [000138] The modified container 100 may be standalone or may be stacked on top of each other as shown in arrangement 900 in Fig. 9. For example, two modified containers 100 may be stacked. The upper and lower modified containers 100 are positively connected to avoid toppling of the modified containers 100 under lateral loads, such as wind and seismic loading. The positive connection can be achieved using the twist lock spacer container locks, i.e. twist lock castings 920.

[000139] The modified container 100 may be transported by road 1000 as shown in Fig. 10 and rail in single high configuration, using the internal standard container twist lock configuration 910 anchored to concrete footing. In preferred arrangements, modified containers 100 are not transported in the stacked configuration.

[000140] The modified containers may be lifted using a standard forklift applied through the fork tyne pockets located at floor level. As shown in Fig. 12, the modified containers may be lifted using a suitable crane with soft slings 1210 attached to the lower external twist lock castings 1220, extending above roof height and meeting at the crane hook above roof level. In the arrangement 1200, the sling angle can be 60 degrees or more. In alternative arrangements 1100 as shown in Fig. 11, the modified containers 100 may be lifted using a suitable crane with chain wire rope or soft slings 1110 attached to the upper external twist lock castings 1120. In the arrangement 1100, the sling angle can be 60 degrees or more.

[000141] Temporary bracing may be provided where required to ensure stability of the structure during erection. Structural steel may have protective treatment. For example, steelwork may be prepared by abrasive blasting to SA 2.5 or mechanical cleaning and a high build epoxy paint system may be applied as per site specifications. Preparation and application can be in accordance with manufacturer’s recommendations. Workmanship and materials can be in accordance with AS 1627, AS/NZS 2312, AS 2700 & ISO 8501. Structural steel sections colour can be customized as per site specifications. Protective coatings damaged during transport, handling and construction can be reinstated in accordance with the specification as soon as practical after damage has occurred.

Industrial applicability

[000142] The arrangements described are applicable to the industry of prefabricated buildings and particularly for prefabricated modular homes, offices or other type of buildings. [000143] The foregoing describes only some embodiments of the present invention, and modifications and/or changes can be made thereto without departing from the scope and spirit of the invention, the embodiments being illustrative and not restrictive.

[000144] In the context of this specification, the word “comprising” means “including principally but not necessarily solely” or “having” or “including”, and not “consisting only of’. Variations of the word "comprising", such as “comprise” and “comprises” have correspondingly varied meanings.

[000145] Reference to background art or other prior art in this specification is not to be construed as an admission that such background art or other prior art is common general knowledge in Australia or elsewhere.