U.S. patent application number 10/943667 was filed with the patent office on 2005-03-31 for hurricane proof modular building structure.
Invention is credited to Bedell, Rick, Moss, Paul Neal.
Application Number | 20050066589 10/943667 |
Document ID | / |
Family ID | 34381248 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050066589 |
Kind Code |
A1 |
Bedell, Rick ; et
al. |
March 31, 2005 |
Hurricane proof modular building structure
Abstract
Disclosed is a modular hurricane proof modular building
structure. The structure includes a dual wall system that includes
a rugged exterior constructed primarily of concrete and steel and a
finished interior, with a thermal break in-between to prevent heat
from the concrete and metallic structure from heating the interior
surfaces. The thermal break also prevents moisture and water vapor
transfer, and therefore, significantly reduces mold growth. The
building combines the best of industry desired characteristics in a
single modular constructed building, combining hurricane force wind
resistance, relocateability, modularity, fire and heat resistance,
mold resistance and substantial concrete construction.
Inventors: |
Bedell, Rick; (Bristol,
IN) ; Moss, Paul Neal; (Constantine, MI) |
Correspondence
Address: |
WHYTE HIRSCHBOECK DUDEK S C
555 EAST WELLS STREET
SUITE 1900
MILWAUKEE
WI
53202
US
|
Family ID: |
34381248 |
Appl. No.: |
10/943667 |
Filed: |
September 17, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60506498 |
Sep 26, 2003 |
|
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Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04B 1/34815 20130101;
E04H 9/14 20130101 |
Class at
Publication: |
052/079.1 |
International
Class: |
E04H 001/00 |
Claims
What is claimed is:
1. A floor structure for use in a hurricane proof modular building
structure, the floor structure comprising: a first floor structure
portion comprising: a plurality of metal support structures; a
non-composite deck disposed on top of the support structures; and a
metal cross-member connected to the metal support structures; and a
second floor structure portion comprising: a second plurality of
metal support structures; a second non-composite deck disposed on
top of the support structures; and a second metal cross-member
connected to the metal support structures; wherein the first and
second metal cross members are in opposing, spaced apart
relationship with respect to each other to define a floor seam that
permits separation of the floor structure along the floor seam.
2. The floor structure of claim 1 wherein the first and second
floor structure portions do not include either a plumbing entry or
a plumbing discharge.
3. The floor structure of claim 1 wherein the first and second
floor structure portions do not include any knockout sections.
4. The floor structure of claim 1 wherein the floor structure is
designed for a 50 PSF live load.
5. The floor structure of claim 1 further comprising a concrete
deck layer formed over the non-composite deck.
6. A wall structure for use in a hurricane proof modular building
structure, the wall structure comprising: an outer concrete layer;
a plurality of metal studs spaced apart from each other and
positioned adjacent to, but separated from, the concrete layer, to
create metal stud-concrete layer thermal gaps; a first insulation
layer located between the plurality of metal studs and adjacent the
concrete layer; a second insulation layer positioned adjacent the
first insulation layer; and a mold resistant layer located adjacent
the second insulation layer; wherein the plurality of thermal gaps
and at least one of the first and the second insulation layers
create a thermal break.
7. The wall structure of claim 6 wherein the concrete layer is of
prescribed thickness and density so as to create a
moisture-impermeable external vapor barrier.
8. The wall structure of claim 7 wherein the vapor barrier and
thermal break create substantially mold-resistant conditions within
the wall structure.
9. A roof structure for use in a hurricane proof modular building
structure, the roof structure comprising: a roof portion having
load-bearing perimeter; an inclined roof comprising opposing
slanted portions reaching a central apex such that the apex of the
slanted portions does not extend above the load-bearing
perimeter.
10. The roof structure of claim 9, wherein the inclined roof
further comprises first and second opposingly inclined roof
structure portions that are in spaced apart relationship with
respect to each other to define a roof seam that permits separation
of the inclined roof along the roof seam.
11. The roof structure of claim 9 wherein the load-bearing
perimeter roof portion permits stacking of a plurality of roof
structures and drainage along the two opposing slated portions.
12. The roof structure of claim 9 wherein the first and second roof
portions are disposed below the perimeter so as to receive another
modular structure thereon.
13. The roof structure of claim 9 wherein the roof structure is
designed for a 30 PSF live load snow-to-ground load.
14. A hurricane proof modular building structure comprising: a
floor structure for use in a hurricane proof modular building
structure, the floor structure comprising: a first floor structure
portion comprising: a plurality of metal support structures; a
non-composite deck disposed on top of the support structures; and a
metal cross-member connected to the metal support structures; and a
second floor structure portion comprising: a second plurality of
metal support structures; a second non-composite deck disposed on
top of the support structures; and a second metal cross-member
connected to the metal support structures; wherein the first and
second metal cross members are in opposing, spaced apart
relationship with respect to each other to define a floor seam that
permits separation of the floor structure along the floor seam; a
wall structure for use in a hurricane proof modular building
structure, the wall structure comprising: an outer concrete layer;
a plurality of metal studs spaced apart from each other and
positioned adjacent to, but separated from, the concrete layer, to
create metal stud-concrete layer thermal gaps; a first insulation
layer located between the plurality of metal studs and adjacent the
concrete layer; a second insulation layer positioned adjacent the
first insulation layer; and a mold resistant layer located adjacent
the second insulation layer; wherein the plurality of thermal gaps
and at least one of the first and the second insulation layers
create a thermal break; and a roof structure for use in a hurricane
proof modular building structure, the roof structure comprising: a
roof portion having load-bearing perimeter; an inclined roof
comprising opposing slanted portions reaching a central apex such
that the apex of the slanted portions does not extend above the
load-bearing perimeter.
15. The hurricane proof modular building structure of claim 14 a
thermal break and a moisture barrier.
16. The hurricane proof modular building structure of claim 14
further comprising a poured concrete exterior modular wall that can
withstand a wind speed of at least 150 mph.
17. The hurricane proof modular building structure of claim 14
wherein the building is suitable for human use or habitation.
18. The hurricane proof modular building structure of claim 14
wherein the wall structure further comprises a plumbing entry and a
plumbing discharge, and wherein the plumbing entry and the plumbing
discharge run through at least one of the wall layers.
19 The hurricane proof modular building structure of claim 14
wherein the wall structure further comprises a plumbing entry and a
plumbing discharge, and wherein the plumbing entry and the plumbing
discharge does not run through a floor.
20. The hurricane proof modular building structure of claim 14
wherein the building structure has a combination of hurricane force
wind resistance, relocateability, modularity, fire and heat
resistance, mold resistance and substantial concrete construction.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a nonprovisional of U.S. Patent
Application Ser. No. 60/506,498, filed Sep. 26, 2003, which is
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to modular building
systems, and more particularly to hurricane proof modular building
structures.
[0003] Increasingly, states that are confronted with the
possibility of tropical storms and hurricanes have promulgated
safety standards in the construction of certain buildings aimed at
minimizing damage to those buildings in hurricane-type situations,
in effect requiring the buildings to be "hurricane proof" to the
extent possible, to for example, withstand extremely high level
winds and high velocity projectiles that are associated with such
wind levels. In response, the industry has moved towards concrete
construction. In the modular building industry, it is a continuing
design goal to meet or exceed the state imposed construction
parameters for hurricane-resistance, and at the same time maintain
a level of portability for the modularly constructed buildings.
[0004] Modularly constructed building structures are advantageous
in that they provide shelter from the elements in which a variety
of activities can be housed, and are relatively easily transported
from one locale to another. Moreover, such structures can typically
be assembled in stackable sections, or sections placed side-by-side
(i.e., the sections are positioned adjacent each other), right on
site after being transported. Modular building structures can be
used for production of single and multi-unit or multi-family homes,
as well as apartments, condominiums, classrooms, general offices,
medical facilities, commercial buildings and the like.
[0005] Further, in the modular building structure industry, there
are increasing requirements and market forces aimed at improving
the structure resistance to mold and combustion. It has been found
that there is a need for a modular building with substantial
concrete construction, therefore meeting the hurricane-proof
requirements, as well as providing a fire-resistant (or
non-combustible) structure with mold-resistant characteristics.
[0006] One construction technique to address the above includes
building a wall within a wall. However, such a procedure promotes
heat transfer and moisture/vapor transfer that leads to mold
growth. A need exists to improve the wall within a wall
construction to create thermal barriers and moisture/vapor
barriers.
[0007] Many modular building structures are custom designed.
However, building structures can also be designed according to
standard or pre-fabricated building templates as well. Today's
modular building structures are computer-engineered to meet
national building codes. They can be precisely engineered for
increased structural durability. High quality can be maintained by
inspection during construction process. In one construction
example, a modular building structure is delivered to a desired
site, after which individual modular structures or "modules" are
assembled into an overall modular building structure.
[0008] In general, the metrics of building construction costs break
out on a per square foot basis. It is a continuous goal to reduce
the construction costs of the modular structures. To this end, it
would be desirable to provide a modular building structure that,
while meeting all applicable building codes and other standards, is
simpler to construct than known modular building structures. For
example, a building structure comprising fewer pieces, parts or
other components in its construction is desirable. Similarly,
material selection for such modular building structures is key, in
that the material type and placement can result in a building
structure of having a greater useful life and durability.
[0009] It would also be desirable to use stronger and more durable
modules or substructures in making the overall modular building
structure. This can lead to a decrease in the number of supports or
braces in a given area, thereby reducing modular building structure
costs on a square foot basis.
[0010] Accordingly, it would be desirable to provide a modular
building structure that combines the best of industry desired
characteristics in a single modular constructed building, combining
hurricane force wind resistance, relocateability, modularity, fire
and heat resistance, mold resistance and substantial concrete
construction.
SUMMARY OF THE INVENTION
[0011] This invention relates generally to a hurricane proof
modular building structure, and more specifically to a hurricane
proof modular building structure that has a combination of
hurricane force wind resistance, relocateability, modularity, fire
and heat resistance, mold resistance and substantial concrete
construction.
[0012] In one aspect of the invention, a hurricane proof modular
building structure is disclosed. The building structure includes a
floor structure for use in a hurricane proof modular building
structure. The floor structure includes: a first floor structure
portion and a second floor structure portion each comprising: a
plurality of metal support structures; a non-composite deck
disposed on top of the support structures; and a metal cross-member
connected to the metal support structures. The first and second
metal cross members are in opposing, spaced apart relationship with
respect to each other to define a floor seam that permits
separation of the floor structure along the floor seam;
[0013] The building also includes a wall structure comprising: an
outer concrete layer; a plurality of metal studs spaced apart from
each other and positioned adjacent to, but separated from, the
concrete layer, to create metal stud-concrete layer thermal gaps; a
first insulation layer located between the plurality of metal studs
and adjacent the concrete layer; a second insulation layer
positioned adjacent the first insulation layer; and a mold
resistant layer located adjacent the second insulation layer. The
plurality of thermal gaps and at least one of the first and the
second insulation layers create a thermal break. The structure also
includes a roof structure, the roof structure comprising: a roof
portion having load-bearing perimeter; and an inclined roof
comprising opposing slanted portions reaching a central apex such
that the apex of the slanted portions does not extend above the
load-bearing perimeter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the invention are disclosed with reference to
the accompanying drawings and are for illustrative purposes only.
The invention is not limited in its application to the details of
construction or the arrangement of the components illustrated in
the drawings. The invention is capable of other embodiments or of
being practiced or carried out in other various ways. Like
reference numerals are used to indicate like components.
[0015] FIG. 1 is a perspective view of one embodiment of a
hurricane proof modular building structure according to one aspect
of the present invention;
[0016] FIG. 2 is top view illustrating a floor plan of the
hurricane proof modular building structure of FIG. 1;
[0017] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 1;
[0018] FIG. 4 is a cross-sectional view taken along line 4-4 of
FIG. 1;
[0019] FIG. 5 is an enlarged detailed view of a portion of the
hurricane proof modular building structure shown in FIG. 4;
[0020] FIG. 6 is an enlarged detailed view of a portion of the
hurricane proof modular building structure taken along line 6-6 of
FIG. 2; and
[0021] FIG. 7 is a perspective view of a plurality of hurricane
proof modular building structures showing their modularity and
stackability.
DETAILED DESCRIPTION
[0022] FIG. 1 is a perspective view of one embodiment of a
hurricane proof modular building structure 10 according to one
aspect of the present invention. By "hurricane proof" it is meant
that the structure is built to withstand and be resistant to high
winds (e.g., tropical storm level winds up to about 75 mph,
hurricane force winds from about 75 mph up to about 150 mph, and
the like). The structure is "modular" in that the structure is
designed an built with standardized units or dimensions so as to
promote ease of assembly and repair. As will be described in
greater detail below, each such structure is built from
prefabricated and standardized parts and/or component pieces.
Various applications are intended and contemplated for the
structure shown, and these include: single and multi-unit or
multi-family homes, as well as apartments, condominiums, support
facilities, general offices, medical facilities, light
manufacturing, commercial buildings and the like, although, in a
preferred embodiment, the structure can be used for a classroom. In
a typical construction, the modular building structure can include
such features as door 12 and windows 14, replicating features found
in permanent building structures.
[0023] As shown, the structure 10 is generally rectangular,
although other shapes are contemplated and considered within the
scope of the present invention. Structure 10 includes a roof
structure 16 that typically inclined downwardly from a roof
centerline or apex 18 to promote drainage of water off of or away
from the roof via, as shown, drainage pipes 20 to a grounded
location. The structure shown represents a combination of two half
modular sections placed together and connected (as will be shown
and described in following) in side-by-side fashion along line 22
after being delivered to the site of use. The structure shown and
described herein represents a culmination of a transition or trend
in the modular building marketplace towards what is referred to as
"concrete construction". Accordingly, in one embodiment, the
structure includes walls 24 that is a poured concrete wall. The
walls, notwithstanding the windows, renders the structure
substantially bullet-proof.
[0024] The structure 10 is constructed for several design
parameters, for example, the floor structure 36 of FIG. 5 is
designed for a 50 PSF live load; roof structure 16 is designed for
a 30 PSF live load snow-to-ground load; and the overall structure
10 is designed to withstand an overall wind speed of 150 mph, and a
class C wind exposure.
[0025] Advantageously, structure 10 (i.e., both its exterior and in
its interior) can be delivered to a site as a substantially
complete module (i.e., about 95% finished). This results in a cost
reduction for the user, and decreases time to use (e.g., on the
order of about a day or two) from the time of delivery of module
structure 10 to the site of use.
[0026] FIG. 2 is top view illustrating a floor plan of the
hurricane proof modular building structure of FIG. 1. Doors 12 are
shown in an open position. Centerline 22 delineates the location at
which the two half modular sections 26a-b are combined to create
the overall building structure 10. One advantage of this structure
design is that each of the sections 26a-b are easily transported to
a specified location. For example, each of the half structures can
be brought separately (e.g., via truck) to a job site. In addition,
each of the structures 26a-b can be used in locations that would
otherwise be inaccessible due to the need to previously transport
structure as a whole. Walls 24 define structure interior portions
28a-b. Because of the high level of structural support provided by
walls 24, portions 28a-b are "open-concept" in that other structure
support members (e.g., beams, pillars, etc.) are not required.
Therefore, a variety of uses can be accomplished within the
interior, and the interior is highly adaptable to such uses.
[0027] FIG. 3 is a cross-sectional view taken along line 3-3 of
FIG. 1, showing the building structure 10, and in particular,
illustrating a recessed roof structure 16, the roof structure
supported by walls 24, connected to a floor structure 40. Roof
structure 16 comprises a raised roof portion 30 defining
load-bearing perimeter, and further including an inclined roof 32
comprising two opposing slanted roof portions 34a-b. The roof
portions are opposingly sloped or pitched so as to reach or define
a central apex 35, which coincides with a roof centerline 18. The
apex of the slanted portions 34a-b does not extend above the
load-bearing perimeter of the roof portion 30, thereby permitting
or facilitating stacking of at least one additional modular
building structure of similar size and shape thereon. Stated
another way, the inclined roof first and second opposingly inclined
roof structure portions are in spaced apart relationship with
respect to each other to define a roof seam that permits separation
of the inclined roof along the seam. Since the raised roof portion
is preferably substantially level, and since the roof is recessed
from the raised roof portion, dual benefits are achieved. Namely,
stacking of a plurality of modular structures is facilitated, while
simultaneously permitting drainage along the two opposing slanted
portions away from the structure itself.
[0028] FIG. 4 is a cross-sectional view taken along line 4-4 of
FIG. 1 showing interior portions 28a-b of half modular sections
26a-b. Although structures 26a-b are separate and distinct, they
are joined to form a single unit in a cohesive fashion, for
example, by common interior finishing of walls 33 and drop ceiling
37. In this way, interior portions 28a-b can be used to create a
single interior space.
[0029] FIG. 5 is an enlarged detailed view of a portion of the
hurricane proof modular building structure shown in FIG. 4.
Specifically, a floor structure 36 for use in the hurricane proof
modular building structure 10 is shown. The floor structure
comprises a first floor structure portion 38 having a plurality of
metal support structures 40 (e.g., steel I-beams), one of which is
shown, and a non-composite deck 42 disposed on top of the support
structures 40. The first floor structure portion 38 includes a
metal cross-member 44 connected to the metal support structures.
The floor structure 36 also includes a second floor structure
portion 46 having a second plurality of metal support structures 48
(again, one of which is shown) and a second non-composite deck 50
disposed on top of the support structures 48. The second floor
structure portion 46 also includes a second metal cross-member 52
connected to the metal support structures 48. The first and second
metal cross members are in opposing, spaced apart relationship with
respect to each other so as to define a floor seam 54 that permits
separation of the floor structure along the floor seam or channel.
The seam or channel 54 can be bridged using, for example, a
lightweight concrete deck. The non-composite deck can comprise, by
way example, a 24 gauge galvanized steel. The floor structure can
be finished by including a concrete deck 43 over the non-composite
deck.
[0030] Advantageously, the inventive floor structure results in a
hurricane proof modular building structure that does not comprise a
knockout floor section. "Knockout" sections are typically used
during the installation of indoor plumbing. "Knockout sections" are
sections that are removable prior to such installation (e.g., at
the site), and then following installation, the sections are
re-poured, for example, with a concrete material.
[0031] FIG. 6 is an enlarged detailed view of a portion of the
hurricane proof modular building structure taken along line 6-6 of
FIG. 2. Referring now to FIGS. 5 and 6, a wall structure 56 for use
in the inventive hurricane proof modular building structure 10
(FIG. 5) is shown in detail. The wall structure comprises an outer
concrete layer 58 and a plurality of metal studs 60 spaced apart
from each other and positioned adjacent to, but separated from, the
concrete layer to create metal stud-concrete layer thermal gaps 62.
The wall structure 56 further includes a first insulation layer 64
located between the plurality of metal studs 60 and adjacent the
concrete layer 58. A second insulation layer 66 is positioned
adjacent the first insulation layer 64 and a mold resistant layer
68 is located adjacent the second insulation layer 66. The
plurality of thermal gaps 62 and at least one of the first and the
second insulation layers 64, 66 are utilized to create a thermal
break 70, and a plurality of thermal breaks are included in the
structure. Typically, the concrete layer 58 is of prescribed
thickness and density so as to create a moisture-impermeable
external vapor barrier. And the vapor barrier and thermal break
create substantially mold-resistant conditions within the wall
structure. Advantageously, hurricane proof modular building
structure comprising a vapor proof wall section. The building
structure can include a poured concrete exterior modular wall
section having a finished interior wall. It can be said that the
hurricane proof modular building structure comprises a wall within
a wall, providing both a thermal break and a moisture barrier. In
one embodiment, a foam seal insulation system can be used to
provide the thermal break, eliminating the need to use mechanical
fasteners.
[0032] Advantageously, the wall structure is provided with both a
plumbing entry and a plumbing discharge to permit indoor plumbing
while also providing for ease of hook up and disconnect to enhance
and facilitate mobility of the structures. In such embodiments, it
can be said that the plumbing entry and the plumbing discharge do
not run through the building structure floor. Because the plumbing
entry and discharge can be positioned to run above the floor, and
through the exterior wall (as opposed to through the floor), there
is no need to utilize a "knock-out" portion of the floor during
plumbing installation at the site.
[0033] The present invention provides a wall structure that
includes a space defined by the steel studs and the concrete walls,
as well as insulation between the steel studs and the interior
drywall, in order to create a thermal break. The concrete provides
a built-in, external vapor barrier. The combination of the vapor
barrier and the thermal break serves to eliminate conditions that
allow mold to form, such as mold that results from moisture and
temperature change-induced condensation.
[0034] Referring to FIG. 5, roof structure 16 is supported by
structural steel make beam 72 embedded on a light track 74 and
cross beam steel joist 75, joined by steel angles 76, which support
roofing materials, such as corrugated deck pan 78. A roofing
material 80 (e.g., EPDM) may be applied over the deck pan 78.
Between roofing material 80 and deck pan 78 is a layer (e.g., 2
inches in thickness) of insulation material (e.g., polyiso) to
provide additional insulation and heat retention within structure
10. The advantage of using a steel I-beam, as opposed to, for
example, a cast concrete I-beam, provides for a reduced-weight
construction, which enhances portability of the structures.
[0035] FIG. 7 is a perspective view of a plurality of hurricane
proof modular building structures 10a-c showing both their
modularity and stackability. The modular building structures shown
include a combination of industry-desired characteristics including
hurricane force wind resistance, relocateability, modularity, fire
and heat resistance, mold resistance and substantial concrete
construction. The hurricane proof modular building structure is
suitable for human use or habitation. As shown, the structures are
formed into a modular building structure arrangement that is two
stories high and two structures wide. However, it is contemplated
that other arrangements could be of different height or width, as
applications vary and conditions so dictate. As referenced
previously, the concealed interior slope for drainage, coupled with
external load-bearing vertical wall members results in a design
that provides for such stackability to create multi-story modular
buildings.
[0036] Preferably, in order to eliminate the need for battens to
conceal joints and mechanical fasteners, beveled edge drywall
panels are used and fasteners are covered with spackle. A
specially-designed paint and application system can be used to
spray, for example, for colors at once over the walls to provide a
suitable finish.
[0037] The present invention combines multiple beneficial features
in one composite structure. While the present invention has been
described in terms of the preferred embodiment, it is recognized
that equivalents, alternatives, and modifications, aside from those
expressly stated, are possible and within the scope of the
appending claims.
* * * * *