Aluminum accommodations module and method of constructing same

Abstract

A modular building and a method of constructing a United States Coast Guard certified modular building for utilization on USCG approved vessels, out of aluminum and special Firemaster Marine Blanketing material. Under the method of the present invention, the walls are constructed as to not be connected, allow the fire insulation blanketing to be a prime barrier to potential fire hazards. Due to several reasons aluminum can be a better material than steel to utilize for the purpose of marine accommoda tions. Aluminum is considerably lighter, due to the crane capacities on offshore floating platforms and boats, the lighter the building the safer it is to lift.

1 . An accommodations module, comprising:
 a. an interior structure constructed of lightweight metal, such as aluminum, for housing workers;   b. an exterior structure constructed of lightweight metal, such as aluminum, for surrounding the entire interior structure;   c. a space provided between walls of the interior structure and walls of the exterior structure, so that there is no contact between the two structures;   d. an insulation material enveloping the interior structure and occupying some of the space between the two structures;   e. the insulation and space between the structures defining a means to reduce or eliminate the transfer of heat from a fire or force from a blast occurring outside of the exterior structure to be transferred into the interior structure.   
     
     
         2 . The module in  claim 1 , wherein the insulation comprises 2″ (5 cm) thick Firemaster Marine Blanket, Calcium Magnesium-Silicate Fiber Insulation with at least an A-60 fire rating. 
     
     
         3 . The module in  claim 1 , wherein the module sizes range preferably from a 12′×20″×10′-6″ (3.7 m×6.0 m×3.2 m), to 16′×70″×10′-6″ (4.9 m×21 m×3.2 m). 
     
     
         4 . The module in  claim 1 , wherein the walls are constructed as to not be connected, and allow the fire insulation blanketing to be a prime barrier to potential fire hazards. 
     
     
         5 . The module in  claim 1 , wherein the walls constructed of aluminum do not corrode (oxidize) nearly as fast as steel in a salt laden marine environment. 
     
     
         6 . A method of constructing an accommodations module, comprising the following steps:
 a. constructing an interior structure of lightweight metal, such as aluminum, for housing workers therein;   b. constructing an exterior structure constructed lightweight metal, such as aluminum of dimensions larger than the interior structure;   c. enveloping walls of the interior structure with an insulation material which resists heat and blast force;   d. placing the exterior structure over the interior structure so that there is defined a void between the insulated walls of the interior structure and walls of the exterior structure, with no direct contact between the two structures;   e. allowing the walls of the exterior structure to be impacted by heat from a fire outside of the exterior structure so that the void and the insulation between the structures define a means to reduce or eliminate the transfer of heat from the fire or to be transferred into the interior structure; or   f. allowing the walls of the exterior structure to be impacted by blast force from a explosion outside of the exterior structure so that the void and the insulation between the structures define a means to reduce or eliminate the transfer of force from the explosion to walls of the interior structure.   
     
     
         7 . The method in  claim 6 , comprising the further step of allowing the insulation to melt from the fire and define a plastic fire proof coating on the outer wall of the interior structure. 
     
     
         8 . The method in  claim 6 , further comprising the step of allowing air within the void between the structure walls to be vented from the void as the force of the explosion impacts the wall of the outer structure and forces it to move inward toward the wall of the interior structure. 
     
     
         9 . The method in  claim 6 , wherein the step of making no contact between the walls of the two structures reduces or eliminates the possibility of heat transfer directly from the outer structure to the interior structure. 
     
     
         10 . The method in  claim 6 , wherein the module, as constructed comprises the interior structure separate from the exterior structure, thus defining a building inside of a building. 
     
     
         11 . The method in  claim 6 , wherein the external wall of light weight aluminum protects the fire wall blanket insulation material from the exterior environment and provides more structural safety for the building. 
     
     
         12 . The method in  claim 6 , wherein the dual wall system provides more air space for increased insulation benefit for greater efficiency for heating and cooling the building. 
     
     
         13 . An accommodations module, comprising:
 a. an interior structure constructed substantially of lightweight aluminum, for housing workers;   b. an exterior structure constructed of lightweight aluminum, having dimensions greater than the dimensions of the interior structure;   c. a void defined between walls of the interior structure and walls of the exterior structure, when the exterior structure is placed over the interior structure, with no direct contact between the two structures;   d. an insulation material having at least an A-60 fire rating enveloping the interior structure and occupying some of the void between the two structures;   e. the insulation and void between the structures defining a means to reduce or eliminate the transfer of heat from a fire occurring outside of the exterior structure to be transferred into the interior structure.   
     
     
         14 . An accommodations module, comprising:
 a. an interior structure constructed substantially of lightweight aluminum, for housing workers;   b. an exterior structure constructed of lightweight aluminum, having dimensions greater than the dimensions of the interior structure;   c. a void defined between walls of the interior structure and walls of the exterior structure, when the exterior structure is placed over the interior structure, with no direct contact between the two structures;   d. an insulation material having at least an A-60 fire rating enveloping the interior structure and occupying some of the void between the two structures;   e. the insulation and void between the structures defining a means to reduce or eliminate force from damaging the interior structure from an explosion occurring outside of the exterior structure.   
     
     
         15 . A method of fabricating an interior structure within an exterior structure so that an event such as a fire or explosion occurring on the outside of the exterior structure does not harm occupants in the interior structure, the method comprising the following steps:
 a. fabricating the interior structure as a single enclosure of lightweight metal;   b. enveloping the interior structure with an insulation material of at least an A-60 fireproof rating;   c. fabricating an exterior structure larger than the interior structure of likewise a lightweight metal;   d. positioning the exterior structure over the interior structure so that there is defined a void between the interior structure and the exterior structure with no direct contact between the two structures; and   e. allowing the insulation and void space to serve as barriers between heat or force to impact the interior structure and harm occupants therein during a fire or explosion occurring outside of the exterior structure.   
     
     
         16 . The method in  claim 15 , wherein the interior structure is fully insulated and covered by the outer structure, thereby protecting the structural integrity of the inner structure and providing stable support for an upper module that may be stacked and supported by the module from below.