U.S. patent application number 10/997200 was filed with the patent office on 2005-05-26 for pre-fabricated building modules and method of installation.
Invention is credited to Quesada, Jorge de.
Application Number | 20050108957 10/997200 |
Document ID | / |
Family ID | 34595253 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050108957 |
Kind Code |
A1 |
Quesada, Jorge de |
May 26, 2005 |
Pre-fabricated building modules and method of installation
Abstract
A pre-fabricated building module containing components of a
typical multi-story housing project and a corresponding method of
installation. Each module is configurable to provide one of a
variety of room and dual-room layouts. The module's design allows
for road transportation and installation by a tower crane typically
found in most multi-story construction projects. Module embodiments
are provided for enabling drop-in, stack-in, or slide-in
installation in most buildings. Each module is preferably stackable
with another module of the same type and configured to provide a
predetermined amount of support for loads in the surrounding
structure. Each module preferably provides all necessary mechanical
and electrical components including their section of risers and
ventilation shaft, as well as fixtures, fittings, appliances,
cabinets, etc. except for the exterior cladding of perimeter walls
which are designed for on-site installation. Each module preferably
includes panelized interior cladding for built-in room items
enabling sub-assembly prefabrication.
Inventors: |
Quesada, Jorge de; (San
Francisco, CA) |
Correspondence
Address: |
COUDERT BROTHERS LLP
ONE MARKET SPEAR TOWER SUITE 2100
SAN FRANSISCO
CA
94105
US
|
Family ID: |
34595253 |
Appl. No.: |
10/997200 |
Filed: |
November 24, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60525250 |
Nov 25, 2003 |
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Current U.S.
Class: |
52/143 |
Current CPC
Class: |
E04H 1/1266 20130101;
E04B 1/34869 20130101 |
Class at
Publication: |
052/143 |
International
Class: |
E04H 001/12; E04B
001/34 |
Claims
What is claimed is:
1. A stackable prefabricated building module for forming one or
more rooms of a multi-story building located at a first location
and configured for stacking with other stackable prefabricated
building modules, said module comprising: a floor frame for
supporting a floor assembly; a ceiling frame for supporting a
ceiling assembly, wherein stacking of said module with one of said
other modules forms a ceiling cavity between a ceiling assembly of
said module and the floor assembly of said other module, said
ceiling cavity providing space for housing ventilation ducting and
utility equipment therewithin; a plurality of columns extending
vertically from below said floor frame to above said ceiling frame,
one of said columns located at each corner of said module, each of
said columns extending below said floor assembly for providing a
leg for connecting to an adjacent level of said building beneath
said module, wherein said columns support the weight of a
predetermined number of stacked modules as a function of the size
and number of said columns; a plurality of floor edge connectors,
each of said floor edge connectors for coupling said floor assembly
to an adjacent portion of the same floor level of said building;
and a plurality of column connectors, each of said column
connectors installed at the top of a corresponding column for
connection to a leg of one of said other modules positioned
adjacent to and above said module.
2. The module of claim 1, further comprising a vertical shaft
section for providing ventilation and for enclosing a vertical
section of a plurality of risers used for coupling utilities to
each said module, said shaft section including a seal to seal said
shaft section to the shaft sections of any adjoining building
modules above and below said module.
3. The module of claim 1, further comprising a plurality of metal
stud insert panels for framing perimeter wall spaces between said
columns.
4. The module of claim 1, further comprising a plurality of beams
coupling said columns to said ceiling frame and floor frame.
5. The module of claim 1, wherein said module is comprised of
tubular light gauge steel members.
6. The module of claim 1, wherein said adjacent portion is
comprised of wood.
7. The module of claim 1, wherein said adjacent portion is
comprised of steel.
8. The module of claim 1, wherein each of said column connectors
includes one or more plates welded at the top of each column and
having one or more holes therein, said module further comprising
one or more high strength bolts, each said bolt for fastening the
plates of each said column to the adjacent leg of another said
module positioned adjacent to and above said module.
9. The module of claim 8, wherein said holes further provide
lifting points during installation of said module at said first
location.
10. The module of claim 8, wherein each said plate enables the
further coupling of said each said column via welding to the
adjacent leg of another said module positioned adjacent to and
above said module.
11. The module of claim 1, wherein said column connector comprises
one or more plates welded at the top of each column, each said
plate for enabling the coupling of said each said column via
welding to the adjacent leg of another said module positioned
adjacent to and above said module.
12. The module of claim 1, further comprising an air conditioning
unit located in said ceiling cavity and a ceiling access panel for
enabling access to said air conditioning unit.
13. The module of claim 1, further comprising a plurality of
casters disposed to said legs for facilitating movement of said
module during fabrication.
14. The module of claim 1, wherein said floor assembly includes a
concrete topping disposed on a steel deck supported by steel
joists.
15. The module of claim 14, wherein a coiled steel bar insert is
embedded into said concrete topping for enabling attachment of
threaded steel bar dowels at the perimeter of said floor assembly
of said module, to enable said concrete floor topping to be
structurally connected to the concrete structural floor of an
adjacent level of said building so as to provide further resistance
to lateral loads.
16. The module of claim 1, wherein said module is the lowest module
of said stack and for installation on the lowest floor of said
building, said module forming a foundation cavity for accommodating
said floor assembly and its attachment to a foundation of said
building, the legs of said module sized to be welded to a base
steel plate anchored into a base foundation of said building when
said module is installed at said first location.
17. The module of claim 1, further comprising bent steel plate
hangers welded to said floor frame of said module for providing
support for an adjacent floor assembly.
18. The module of claim 1, further comprising a threaded bar
coupled to an end of said leg to enable leveling with adjacent
levels.
19. The module of claim 1, wherein perimeter walls are formed on
said module, said perimeter walls having an exterior surface and a
cladding thereon.
20. The module of claim 15, further comprising diagonal steel
bracing member positioned between said columns at said perimeter
walls for providing increased resistance to lateral loads.
21. The module of claim 16, wherein said diagonal steel bracing is
about the same thickness as said columns such that said bracing is
concealed and fire-protected by said perimeter wall cladding.
22. The module of claim 1, wherein said module is fabricated at a
second location and is adapted to be handled and transported on a
vehicle on a public road for transporting said module from said
second location to said first location.
23. The module of claim 2, wherein each shaft section includes an
access door for enabling connection to said risers and a grating to
enable air flow.
24. The module of claim 1, wherein said building is a preexisting
building having one or more other stacked modules and said module
is installed at said first location by stacking said module with
said other stacked modules in said building, said module providing
a predetermined amount of support for loads of the surrounding
structure of said building.
25. The module of claim 1, wherein said module is inserted from a
top of said building and does not support for the loads of the
surrounding structure of said building.
26. A prefabricated building module for forming one or more rooms
of a building located at a first location and configured to be
slidable into an opening of said building for installation, said
module comprising: a floor frame for supporting a floor assembly; a
ceiling frame for supporting a ceiling assembly; a plurality of
columns extending vertically from below said floor frame to above
said ceiling frame, one of said columns located at each corner of
said module; a plurality of floor edge connectors, each of said
floor edge connectors for coupling said floor assembly to an
adjacent portion of the same floor level of said building; and a
plurality of column connectors, each of said column connectors
installed at the top of a corresponding column; wherein said module
enables connection to the risers of said building used for coupling
utilities to each said module.
27. The module of claim 26, wherein said module is attached to said
building via a plurality of steel angles.
28. A method for storage and transport of a prefabricated building
module, said module to be installed in a building at a first
location comprising the steps of: providing at least one upper
connecting steel plate for lifting said module during fabrication
at a second location; attaching wood members to each said plate;
installing a temporary roof cover supported by said wood members;
installing tubular steel legs extending from the bottom of said
module at each corner; attaching wood sleepers via threaded rods at
the bottom of said tubular steel legs so that said module is
suitable for transportation; and after fabrication, with said
temporary roof cover in place, wrapping said module with a
tear-resistance waterproof protective membrane secured by wood
strips at the bottom of the module.
29. The method of claim 28, further comprising the steps of
removing said membrane, said wood strips, and said temporary roof
cover before installation of said module in said building; and
removing said wood sleepers once said module is lifted by a crane
for permanent installation in said building.
30. The method of claim 28, further comprising the step of
attaching a plurality of casters to said tubular steel legs to
facilitate movement of said module during fabrication, said casters
being removed prior to transport of said module.
31. The method of claim 28, wherein said legs and said at least one
upper connecting steel plate are attached to said module at said
first location.
32. A method of installation of a prefabricated building module
into a building at a first location comprising the steps of:
fabricating said module at a second location a distance away from
said first location; transporting said module to said first
location; sliding said building module into an opening of said
building; and coupling said module to a plurality of risers housed
within a shaft of said building for connecting said module to
utilities and ventilation systems therein.
33. A method of installation of a prefabricated stackable building
module into a building at a first location, said module having a
vertical shaft section for providing ventilation and for enclosing
a vertical section of a plurality of risers, comprising the steps
of: fabricating said module at a second location a distance away
from said first location; transporting said module to said first
location; inserting said module from a top of said building into a
cavity in said building via a crane; and operatively connecting
said shaft section to a shaft section of one or more adjacent
stackable modules; each said shaft section including a seal such
that said shaft sections of adjoining building modules are
automatically sealed during installation of said module.
34. The method of claim 33, wherein said inserting step comprises
stacking said module onto a stack of one or more other
prefabricated stackable building modules via a crane; said module
providing a predetermined amount of support for loads of the
surrounding structure of said building, and further comprising the
step of connecting said module to said building such that said
module provides a predetermined amount of support for loads in the
surrounding structure of said building.
35. The module of claim 1, further comprising panelized interior
cladding for built-in room items enabling sub-assembly fabrication
thereof.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/525,250 filed Nov. 25, 2003.
FIELD OF INVENTION
[0002] The present invention relates in general to modular building
construction systems and, more particularly, to an apparatus and
method for pre-fabricated building modules for use in the
construction of building structures.
BACKGROUND OF INVENTION
[0003] The cost of construction of a typical multi-story housing
project includes significant material and labor costs. The labor
costs are increased by the need for the use of specialized workers
of many trades on site. The time spent by these specialized workers
and the specialization required is heightened by the need for
construction to be done on site. Costs and specialization are
enhanced by the need for on-site construction to be done in
confined spaces. Typically, due to the confined spaces and location
of the work site, on-site construction is not performed using the
most current fabrication technologies. Thus, on-site construction
does not present the most advantageous industrial environment.
[0004] On-site housing construction has the drawback of not taking
full advantage of the benefit of economies of scale experienced by
other industries operating in a modern automated factory setting.
As a result, the inefficiencies inherent in on-site construction
result in wasted time and effort thereby increasing the cost of
construction. A need therefore exists for a building module that is
pre-fabricated in the most advantageous industrial environment
using the most modern fabrication technologies.
[0005] The bathrooms and kitchens are typically the most expensive
components of a housing project because these rooms require more
construction time due to the confined spaces and features of these
rooms. What is also needed therefore is a pre-fabricated finished
building modules and corresponding method of installation for
reducing construction time, especially as compared with on-site
construction.
[0006] Pre-fabricated building modules must be transported to the
construction site for installation. Public regulations generally
limit the dimensions of loads that can be transported via the
public roads. A need therefore exists for a lightweight
manufactured building module that can be transported on public
roads. Building modules which are bulky can require specialized
cranes or similar equipment for installation. A need therefore also
exists for a lightweight manufactured building module that can be
readily installed via a tower crane of the type typically used in
most multi-story construction projects. Housing projects vary in
their size and layout. A need therefore exists for building modules
that are readily configurable off site into various preselected
room components.
[0007] Many housing projects such as condominiums, hotels,
apartments, etc. have multiple stories, each configured similarly.
For example, a component such as a bathroom on one floor of the
building is often located above and below an identical bathroom on
another floor. Typically, each room of the project is constructed
on site. A more efficient and less costly means is needed for
construction of components of such buildings. A need therefore
exists for pre-fabricated building modules and a corresponding
method of installation for efficiently placing the modules in a
suitable building. A need also exists for pre-fabricated stackable
building modules (SBMs) and a corresponding method of installation
that enables stacking of the pre-fabricated modules for efficiently
placing the units in a suitable building.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the drawbacks of known
building modules and methods by providing lightweight
pre-fabricated building modules containing components of a typical
multi-story housing project. The modules are configurable for most
components of a typical housing unit including the bathroom and
kitchen, typically the most expensive components in a housing
project. The building modules are configurable to provide other
building components such as powder rooms, laundries, other
specialized facilities, and floor-to-floor sections of completed
stair and elevator shafts. The building module can be used in
various applications such as, hotels, dormitories, barracks,
hospitals, etc.
[0009] An advantage of the present invention is that is provides
building modules for production in an industrial environment using
modern fabrication technologies. The use of industrialized
production has the benefit of providing large economies of cost of
construction and in construction time when compared with on-situ
conventional construction involving many trades working in rather
confined spaces.
[0010] Another advantage of the present invention is that the
building modules lightweight design allows for road transportation
and installation by a tower crane of the type usually found in most
multi-story construction projects.
[0011] Another advantage of the present invention is that the
building modules are finished units. Typically each module contains
the necessary mechanical and electrical components including their
section of risers and ventilation shaft, as well as sanitary
fixtures and fittings, appliances, cabinetwork, interior finishes,
etc. One exception to complete pre-fabrication off site is that the
perimeter walls outside cladding is to be installed in-situ in
order to allow for the completion of the electrical installation of
the adjacent rooms.
[0012] Still another advantage of the present invention is that the
use of panelized interior cladding, which includes built-in items
such as medicine cabinets, paper holders, etc., allows for
sub-assembly fabrication and contracting, as well as simplifying
maintenance and future renovation.
[0013] Another advantage of the present invention is that the
building modules can be designed in many varied designs,
combinations, and configurations, e.g., dual-bathroom, dual
kitchen, bathroom-kitchen combination to suit most building
conditions.
[0014] Another advantage of the present invention is that the
building modules are compatible with different types of
construction such as wood frame, light gauge steel, hot rolled
steel, pour-in-place concrete, pre-stressed concrete, etc.
[0015] Another advantage of the present invention is that it
provides for integration within stackable modules of overhead air
conditioning equipment.
[0016] Another advantage of the present invention is that it
provides various methods of installing the building modules of a
given design layout in order to conform to different building
conditions, such as a "stack-in", "drop-in" and "slide-in"
installation types.
[0017] Another advantage of the present invention is that it
provides the ability to structural connect the concrete floor
topping of the module with the adjacent floor's (or roofs) concrete
structural floor (or roof) by means of steel dowels inserted at the
perimeter of the module floor. Thus, the module has the advantage
of allowing for a continuous floor diaphragm so as to aid in
resisting lateral loads, e.g., seismic and wind.
[0018] Broadly stated, the present invention provides a stackable
prefabricated building module for forming one or more rooms of a
multi-story building located at a first location and configured for
stacking with other stackable prefabricated building modules, said
module comprising a floor frame for supporting a floor assembly; a
ceiling frame for supporting a ceiling assembly, wherein stacking
of said module with one of said other modules forms a ceiling
cavity between a ceiling assembly of said module and the floor
assembly of said other module, said ceiling cavity providing space
for housing ventilation ducting and utility equipment therewithin;
a plurality of columns extending vertically from below said floor
frame to above said ceiling frame, one of said columns located at
each corner of said module, each of said columns extending below
said floor assembly for providing a leg for connecting to an
adjacent level of said building beneath said module, wherein said
columns support the weight of a predetermined number of stacked
modules as a function of the size and number of said columns; a
plurality of floor edge connectors, each of said floor edge
connectors for coupling said floor assembly to an adjacent portion
of the same floor level of said building; and a plurality of column
connectors, each of said column connectors installed at the top of
a corresponding column for connection to a leg of one of said other
modules positioned adjacent to and above said module.
[0019] According to another embodiment, broadly stated, the present
invention provides a prefabricated building module for forming one
or more rooms of a building located at a first location and
configured to be slidable into an opening of said building for
installation, said module comprising a floor frame for supporting a
floor assembly; a ceiling frame for supporting a ceiling assembly;
a plurality of columns extending vertically from below said floor
frame to above said ceiling frame, one of said columns located at
each corner of said module; a plurality of floor edge connectors,
each of said floor edge connectors for coupling said floor assembly
to an adjacent portion of the same floor level of said building;
and a plurality of column connectors, each of said column
connectors installed at the top of a corresponding column; wherein
said module enables connection to the risers of said building used
for coupling utilities to each said module.
[0020] According to another embodiment, broadly stated, the present
invention provides a method of installation of a prefabricated
stackable building module into a building at a first location, said
module having a vertical shaft section for providing ventilation
and for enclosing a vertical section of a plurality of risers,
comprising the steps of fabricating said module at a second
location a distance away from said first location; transporting
said module to said first location; inserting said module from a
top of said building into a cavity in said building via a crane;
and operatively connecting said shaft section to a shaft section of
one or more adjacent stackable modules; each said shaft section
including a seal such that said shaft sections of adjoining
building modules are automatically sealed during installation of
said module.
[0021] According to another embodiment, broadly stated, the present
invention provides a method of installation of a prefabricated
building module into a building at a first location comprising the
steps of fabricating said module at a second location a distance
away from said first location; transporting said module to said
first location; sliding said building module into an opening of
said building; and coupling said module to a plurality of risers
housed within a shaft of said building for connecting said module
to utilities and ventilation systems therein.
[0022] According to another embodiment, broadly stated, the present
invention provides a method for storage and transport of a
prefabricated building module, said module to be installed in a
building at a first location comprising the steps of providing at
least one upper connecting steel plate for lifting said module
during fabrication at a second location; attaching wood members to
each said plate; installing a temporary roof cover supported by
said wood members; installing tubular steel legs extending from the
bottom of said module at each corner; attaching wood sleepers via
threaded rods at the bottom of said tubular steel legs so that said
module is suitable for transportation; and after fabrication, with
said temporary roof cover in place, wrapping said module with a
tear-resistance waterproof protective membrane secured by wood
strips at the bottom of the module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The foregoing aspects and the attendant advantages of the
present invention will become more readily appreciated by reference
to the following detailed description, when taken in conjunction
with the accompanying drawings, wherein:
[0024] FIG. 1 illustrates a top view floor plan of a preferred
embodiment of the module according to the present invention that
includes two bathrooms in a back-to-back, dual bathroom,
configuration.
[0025] FIG. 2 illustrates an enlarged area of FIG. 1 covering the
common vertical shaft;
[0026] FIG. 3 illustrates a side sectional view of the dual
bathroom module in FIG. 1.
[0027] FIG. 4 illustrates a side sectional view of the dual
bathroom module 10 in FIG. 1 shown with its storage and
transportation trim.
[0028] FIG. 5 illustrates a side sectional view of an embodiment of
an exemplary stack of "stack-in" installation type of building
modules containing four dual bathroom modules within a
building.
[0029] FIG. 6 is a detail view illustrating the typical connection
of a module stack in FIG. 5 with the adjacent supported floors of
light gauge steel construction.
[0030] FIG. 7 is a detail view illustrating the typical connection
of a module stack in FIG. 5 wherein the adjacent supported floors
are comprised of standard wood construction.
[0031] FIG. 8 is a detail view illustrating the typical connection
of a module stack in FIG. 5 wherein the adjacent supported floors
are comprised of standard steel construction using hot rolled
sections.
[0032] FIG. 9 is a detail view illustrating the typical connection
of a module stack in FIG. 5 wherein the adjacent supported floors
include a concrete slab.
[0033] FIG. 10 illustrates a side sectional view of an alternate
embodiment according to present invention of an exemplary stack of
"drop-in" installation type of building modules containing four
dual bathroom modules within a building.
[0034] FIG. 11 illustrates a detail view of the embodiment in FIG.
10 showing the connection of a typical module stack with the
adjacent floors of concrete construction.
[0035] FIG. 11 a is a cross section of area 11 a of FIG. 11 showing
additional details of the removable channel and removable
guide.
[0036] FIG. 11b is a detail view taken along section line 11b of
FIG. 11a.
[0037] FIG. 12 is a detail view similar to FIG. 11 for an
alternative embodiment wherein the surrounded non-supported
structure is of standard steel construction using hot rolled
sections.
[0038] FIG. 13 illustrates a side cross section view of a
"slide-in" installation type embodiment of the module according to
present invention.
[0039] FIG. 14a-14h illustrates exemplary alternate embodiments of
the module according to the present invention for use as bathrooms,
kitchens, powder rooms, laundries, and other types of specialized
facilities.
[0040] FIG. 15 illustrates a fragmentary view of an exemplary
apartment floor plan showing exemplary paired kitchens and
bathrooms modules and their location within the floor layouts.
[0041] FIG. 16a illustrates an exemplary "stack-in" method of
installing the building modules according to an embodiment of the
present invention.
[0042] FIG. 16b illustrates an exemplary "drop-in" method of
installing the building modules according to an embodiment of the
present invention.
[0043] FIG. 16c illustrates an exemplary "slide-in" method of
installing the building modules according to an embodiment of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 illustrates a top view floor plan of a preferred
embodiment of the module 100 according to the present invention
that includes two bathrooms in a back-to-back, dual bathroom,
configuration. The module 10 is also referred to herein as a
dual-bath or dual-bathroom module. Bathrooms 12, 14 in dual
bathroom module 10 preferably have identical bathroom elements and
are shown as mirror images of each other in FIG. 1. As a result,
the description of elements in one bathroom also applies to the
other bathroom in module 10. A tubular steel frame forms the basic
structure of dual bathroom module 10 and includes corner columns
101 and connecting beams 102 at top and bottom. Light gauge metal
stud insert panels 103 are attached to the tubular frame to support
the perimeter wall finishes. The intermediate wall separating the
individual bathrooms 12, 14 contains most of the plumbing
installation as a sub-assembly 104.
[0045] The dual bathroom module 10 includes a common vertical shaft
4 formed by fire rated walls 105. FIG. 2 illustrates a detail view
of the area 2 in FIG. 1 including details for the common vertical
shaft 4. The vertical shaft 4 includes a floor grille 106 for
allowing the vertical flow of exhaust air and a fire-rated access
door/panel 107. The vertical shaft 4 contains the floor-to-floor
segments of a riser 108 for waste, sanitary vent 109, hot and cold
water supply 110, air-conditioning lines 111, and condensate water
drain 112. The vertical shaft preferably contains a riser 108a for
the electrical system and a riser 108b for the fire sprinkler
systems. Module 10 includes a wall mounted exhaust grille 113
preferably having fire-rated shutters.
[0046] For stackable building modules 10, the present invention
integrates accessible ventilation shafts containing floor to floor
sections of risers, as shown in FIGS. 1 and 2. The horizontal joint
between shaft sections of adjacent modules 10 is preferably sealed
by a rated fire resistant resilient tape adhered to the top of the
shaft walls of the lower module. Once a stack of building modules
is installed, the integrated vertical shaft 4 offers continuous
fire protection throughout its entire height, in conformance to
U.S. and international building codes. Access to the mechanical and
electrical risers is provided by means of fire-rated doors, or
through provisional wall openings to be field clad in fire rated
materials such as gypsum board.
[0047] As shown in FIG. 1, dual bathroom module 10 includes the
standard bathroom fixtures and fittings installed for each bathroom
12, 14 including a tub 114, a water closet (toilet) 115, and a
lavatory portion 117. Alternatively, the water closet 115 includes
a tank 116 built into the wall. The lavatory portion 117 preferably
includes a counter 118 and a medicine cabinet 119 built into a
finished wall panel assembly 121. Air conditioning units 136 (shown
in FIG. 3) are preferably included in module 10 and located above a
ceiling 135 (shown in side view in FIG. 3). A ceiling access panel
120 is included for enabling access to the air conditioning unit
136. The dual bathroom module 10 includes a finish wall panel
assembly 121 and a towel rack 122. Module 10 preferably includes an
installed toilet paper dispenser 123. Module 10 includes a bathroom
access door and frame assembly 124. Module 10 preferably includes a
floor finish 125. An outside cladding 126 for the perimeter walls
is installed on-situ in order to allow for the completion of the
electrical installation of adjacent rooms.
[0048] FIG. 3 illustrates a side sectional view of the dual
bathroom module 10 of FIG. 1. As seen in FIG. 3, the module 10
preferably includes tubular steel columns 101 at each corner sized
to support the weight of a full stack of bathrooms and resist
lateral loads when required. Module 10 includes steel beams 102, of
tubular or W sections, connecting the columns 101 at the floor and
ceiling levels. The columns 101 project below the floor level
thereby functioning as "legs" 129 for connecting to the lower
module. The tubular steel legs 129 have a welded steel plate end
cover and a threaded steel bar 130 (shown in FIG. 4) serving as a
leveling device. At each corner, at the ceiling level, module 10
includes connecting steel plates 131 welded to the top of each
corner columns 101 to receive the legs 129 of the module above. The
legs 129 and the connecting steel plates 131 are attached by means
of high strength bolts 132 and/or welding. In a preferred
embodiment, module 10 includes bolts 132 and welding. Steel joists
127 and a corrugated steel deck 128 of module 10 form the floor
support for a concrete topping 133 and finish floor 125 (above a
waterproof membrane).
[0049] As shown in FIG. 3, module 10 includes light gauge steel
channels 134 supporting a finish ceiling 135. A ceiling access
panel 120 is included to allow access for maintenance of the air
conditioning unit 136. Light gauge steel studs 103 preferably frame
the perimeter (exterior) wall spaces between the corner columns 101
and a wall cavity between the bathrooms which contain the plumbing
assembly 104 (shown in FIG. 1). FIG. 3 also shows the tub 114 and
the water closet 115. A water closet tank 116 is concealed between
the wall cavity. Module 10 includes a glass tub enclosure 138.
Compressible fire-seal tapes 140 are included at the top of the
wall cavity studs. Module 10 includes acoustical batt insulation
140 at the wall cavity. As shown in FIG. 3, adjacent floors 141 are
supported by the bathroom module stack.
[0050] FIG. 3 also shown the perimeter wall outside cladding 126
that is field installed. In an alternate embodiment, diagonal
bracing 137 (shown in phantom in FIG. 3) is provided at the
perimeter walls. The diagonal bracing 137 between the perimeter
steel members aids in resisting lateral forces. The diagonal
bracing is preferably the same thickness as the perimeter steel
members, and thus is concealed and fire protected by the perimeter
wall cladding.
[0051] FIG. 4 illustrates a side sectional view of the dual
bathroom module 10 in FIG. 1 shown with its storage and
transportation trim. Upper connecting steel plates 131 are provided
for lifting module 10 during fabrication, transportation, and
erection to its permanent location within a building structure.
Plates 131 also serve to attach wood members 142 for supporting a
temporary roof cover structure 143. Tubular steel legs 129 project
from the bottom of the module at each corner. Threaded rods 130 at
the bottom of the tubular steel legs 129 enable attachment of wood
sleepers 144 suitable for transportation and casters 145, as
required, to facilitate moving during fabrication. After
fabrication, with the temporary roof framing in place, the module
assembly is wrapped tightly with a tear-resistance waterproof
protective membrane 146 kept tight in place by wood strips 147 at
the bottom of the module. The membrane 146 and wood and temporary
"roof` framing 143 are to be removed just before the installation
of the module in a building. The wood sleepers 144 are to be
removed once the module is lifted by a crane for permanent
installation.
[0052] FIG. 5 illustrates a side sectional view of an embodiment of
an exemplary stack 20 of "stack-in" installation type of building
modules containing four dual bathroom modules 10 within a building.
The stack 20 is not only self-supporting but, as shown, also
supports part of the adjacent floors. The bottom legs 148 of the
module 10 on the 1.sup.st floor are customizable to suit the
conditions of a specific project. Stack 20 includes a floor or
foundation cavity 149 required to accommodate the floor of the
lowest module and its attachment to the base structure or
foundation. Although shown in FIG. 5 on the 1.sup.st floor, the
lowest module in the stack 20 need not be on the 1.sup.st floor
depending on the building arrangement. For installation, the bottom
legs 148 of the lowest module 10 are welded to a base steel plate
150 anchored into the base structure/foundation 151. The uppermost
module 10 is to be covered by a cap 152 of similar type
construction. The configuration of the cap structure is adjustable
to meet the conditions of the adjacent roof structure 153. The
construction of the roof cap 152 is preferably similar to the floor
of the module (tubular steel frame, light gauge steel joist, and
corrugated steel deck) including legs at each corner. Once the
erection of a module stack is completed, the riser sections
contained in the vertical shaft, shown best in FIG. 2, are
connected to each other, and the electrical lines and air
conditioning system of the module will be connected with those of
the adjacent structure.
[0053] FIG. 6 is a detail view illustrating the typical connection
of a module stack in FIG. 5 with the adjacent supported floors of
light gauge steel construction. A threaded bar 130 at the end of
the upper module legs 129 serves primarily as a leveling device and
secondarily as an attachment for wood sleepers 144 and casters 145
shown in FIG. 4. High strength steel bolts 132 attach the lower
module to the "leg" of the module above, through slotted holes in a
connecting steel plate 131. Preferably, fillet welding, identified
as 6 in FIG. 6, is included around the connecting steel plate 131
for providing greater load bearing capacity. The use of fillet
welding 6 enables the module stack to be higher than it otherwise
could be when using high strength bolts 132 alone. In an
alternative embodiment (not shown), the fillet welding is used in
place of the bolts 132. The modules stacks such as shown in FIG. 5
are able to be structural self-supporting and also able to support
the loads of a portion of the adjacent floor structure including
vertical and lateral loads, e.g., seismic and wind. The stack
capacity varies with the size and number of perimeter steel columns
101 and the use of high strength bolts 132 and/or fillet welding 6
at the column connections. For example, for an exemplary dual
bathroom module 10 as shown in FIG. 1, having four 6'.times.6"
tubular 1/2" thick steel columns, a stack 12 modules high will be
self-supporting by using four {fraction (3/4)}" A490 high strength
bolts 132 at each attachment. If welded connections 6 are used, a
self-supporting stack of approximately 40 modules high is possible
with 4".times.1/2" steel plate connectors and 27" of {fraction
(7/16)}" fillet welding at each connector plate. Self-supporting
herein refers to gravity loads. The bolt holes at the connecting
steel plate 131 are also useable as lifting points during the
erection of the stack. One bolt at each connecting steel plate 131
can be used temporarily until field welding is effected.
[0054] As seen in FIG. 6, bent steel plates hangers 154 are welded
to the lower tubular steel beams 102 of the upper module for
serving as support for the adjacent floor assemblies. The supported
floor assemblies include light gauge steel joists 155 supporting a
corrugated steel deck 156. Coiled steel bar inserts 157 embedded
into the concrete topping 133 of the module floor allow the
attachment of threaded steel bar dowels 158 prior the pouring of a
concrete topping 159 on the adjacent supported floor. The structure
has a cladding 160 of the exterior surface of the perimeter walls
of the module 10 and a finished ceiling 161 attached to the bottom
of the steel joists of the adjacent floors. As a result, the
capability is provided by the present invention to structural
connect the concrete floor topping of the module with the adjacent
floor's (or roof) concrete structural floor (or roof) by means of
steel dowels inserted at the perimeter of the module floor. This
structure allows for a continuous floor diaphragm which aids in
resisting lateral loads, e.g., seismic and wind.
[0055] FIG. 7 is a detail view illustrating the typical connection
of a module stack in FIG. 5 wherein the adjacent supported floors
are comprised of standard wood construction. Bent steel plate
hangers 154 are welded to the bottom tubular steel beam 102 of the
module above, for providing support for the adjacent wood floors.
Each of the adjacent supported steel floors includes a wood joist
162, a plywood deck 163, a sound barrier sheet 164, and a topping
165 of gypsum or alternatively, lightweight concrete.
[0056] FIG. 8 is a detail view illustrating the typical connection
of a module stack in FIG. 5 wherein the adjacent supported floors
are comprised of standard steel construction using hot rolled
sections. For this embodiment, continuous steel angles 167 are
welded to the lower tubular steel beam 102 of the upper module for
providing support to the adjacent floor of standard steel
construction. Each of the adjacent supported steel floors includes
a corrugated steel deck 168, and a concrete topping 169.
[0057] FIG. 9 is a detail view illustrating the typical connection
of a module stack in FIG. 5 with the adjacent supported floors of
concrete construction.
[0058] FIG. 10 illustrates a side sectional view of an alternate
embodiment according to present invention of an exemplary stack of
"drop-in" installation type of building modules containing four
dual bathroom modules within a building. In this embodiment, the
modules are similar to the module stack in FIGS. 1 and 5, except,
in FIG. 10 the stack of modules, although self-supporting, does not
support any part of the adjacent structure. The modules are
inserted from the top of the building structure through a vertical
shaft of appropriate dimensions.
[0059] FIG. 11 illustrates a detail view of the embodiment in FIG.
10 showing the connection of a typical module stack with the
adjacent floors of concrete construction. The embodiment in FIG. 11
includes an edge of an opening 170 in a concrete structure. The
opening 170 allows the modules to be lowered into position so as to
form the module stack. Removable steel channels 171 are attached to
the edge of the opening 170, two each at opposite sides, to further
facilitate the lowering of the modules. Removable steel guides 172
are attached to the tubular steel columns 101, shown in FIGS. 1 and
3, located at each corner of the module, one guide towards the top
of each module, and other towards the bottom.
[0060] FIG. 11a is a cross section of area 1 a in FIG. 11 showing
additional details of the removable channel 171 and removable guide
172. FIG. 11b is a detail view taken along section line 11b of FIG.
11a. As shown for the embodiment in FIG. 11, once the modules are
leveled and attached to each other, cement grout 173 is poured in
the joint between the module and the surrounding concrete
structure. The grout 173 is contained by a cement board skirt 174
and a removable board at the bottom attached to the concrete
structure by a bolted insert 176 used to attach the removable
channels 171 to the structure.
[0061] FIG. 12 is a detail view of an alternative embodiment of
FIG. 11 wherein the surrounded non-supported structure is made of
standard steel construction using hot rolled sections. In this
alternative embodiment, the space between the module stack and the
surrounding steel structure is to be filled with cement grout 173.
The grout 173 is to be contained by a cement board skirt 174
attached to the module and a removable steel plate 177. The steel
plate 177 is attached by means of threaded bolts 176 welded to the
bottom of a steel member 166 at the edge of the opening.
[0062] FIG. 13 illustrates a side cross section view of a
"slide-in" installation type embodiment of the module according to
present invention. The "slide-in" module 40 is for use in
installations within an individual floor of a building where there
is no stacking requirement. The "slide-in" module 40 requires
connection to the building plumbing and ventilation risers since it
lacks its own risers and ventilation shaft section. The "slide-in"
module 40 also lacks the air conditioning equipment found at the
top of other embodiments of the module so as to facilitate their
installation between two existing floor assemblies. The
installation of the "slide-in" module requires a floor depression
or an opening in the supporting floor structure. The "slide-in"
module is attached to the existing supporting structure via a steel
angle 179 as shown, or by other suitable means. The "slide-in"
module can receive the same storage and transportation trim
protection as shown in FIG. 4, and described above.
[0063] The smaller dimension of the module is generally limited for
transport by road regulations, typically 10 feet for unescorted
transport and 12 feet for escorted ones. The module length is
generally limited to the length of the truck bed, typically 40
feet. Other restraints may exist for specific construction sites.
The building modules of the present invention can be transported
using standard size shipping containers. In this case, the module
overall dimensions are to be limited to 88" in width and in height,
with a maximum length of 230" for 20 feet long containers and 460"
for 40 feet containers. When using shipping containers, the legs
and connector plates are attached at the destination point, as well
as the completion of the installation of overhead air conditioning
equipment. In the case of container transport, the clear floor the
ceiling height within the module is to be 7'-0", which is
acceptable for such small spaces and by the US building codes. For
example; a 40 feet container can be used to transport two sets of
dual bathrooms or dual kitchens or two sets of kitchen/bathroom
modules, or a combination of two of those types. The total weight
of an exemplary pair of such modules is about 24,000 pound, which
is below the 45,000 pound capacity of the typical 40 feet
container.
[0064] FIG. 14a-14h illustrates exemplary alternate embodiments of
the module according to the present invention for use as bathrooms,
kitchens, powder rooms, laundries, and other types of specialized
facilities. FIG. 14a shows an embodiment of a dual-bathroom module,
such as shown in FIG. 1, that includes a pair of bathrooms in a
back-to-back arrangement. FIG. 14b shows an embodiment of a
dual-kitchen module including a pair of kitchens in a back-to-back
arrangement. FIG. 14c shows an embodiment of a module including a
kitchen and a bath in a back-to-back arrangement. FIG. 14d shows an
embodiment of a module including a combination of a kitchen and two
bathrooms. FIG. 14e shows an embodiment of a module including an
individual bathroom. FIG. 14f shows an embodiment of a module
including an individual kitchen. FIG. 14g shows an embodiment of a
floor-to-floor module including a stair shaft. FIG. 14h shows an
embodiment of a floor-to-floor module including an elevator
shaft.
[0065] FIG. 15 illustrates a fragmentary view of an exemplary
apartment floor plan showing exemplary paired kitchens and
bathrooms module embodiments and their location within the floor
layouts. It will be recognized by those skilled in the art that the
module of the present invention is also adaptable for use in
hotels, dormitories, hospitals, barracks, etc.
[0066] The building modules can also be produced in a wide variety
of design layouts and combinations to suit most building
conditions. A variety of installation methods are provided for a
given design layout in order to conform to different building
conditions, such as a "stack-in", "drop-in" and "slide-in"
installation types of modules, as will now be described in further
detail.
[0067] For the various module configuration described above there
are three installation types of building modules. A given module
according to the present invention is adaptable to the different
methods of installation by relatively simple modifications. A first
installation type of building module is a "stack-in" building
module. A stack of this first type of building modules is
self-supporting as well as able to support a certain amount of
tributary floor loads from the surrounding structure. This type of
modules is intended to be installed concurrently with the
surrounding structure. FIG. 16a illustrates an exemplary "stack-in"
module and method of installing the building modules according to
an embodiment of the present invention. As seen in FIG. 16a, a
structure 180 is in the process of being built around a module
stack 50. In this condition, the module stack 50 is self-supporting
and, if properly designed, is able to support adjacent floors. Each
module 182 is installed by means of a crane 183 to create the
stack.
[0068] A second installation type building module (and
corresponding method) is a "drop-in" building module. A stack of
this type is self-supporting, but is not intended to carry loads
from the surrounding structures. As its name implies, this second
type of module is intended for installation through floor openings
within an existing building being remodeled or converted into
housing, or a new structure being completed. FIG. 16b illustrates
an exemplary "drop-in" type module and method of installing the
building modules according to an embodiment of the present
invention. For the "drop-in" type and method, a structure 181 is
built with aligned floor openings able to receive the module stack.
Each module 182 is descended to its floor position by means of the
crane 183 through a vertical shaft in the structure.
[0069] The different module configurations e.g., dual-bathroom,
according to the present invention are useable in a non-stackable
configuration for single family homes and other similar types of
small buildings. A third installation type of building module (and
corresponding method) is a "slide-in" building module. This type of
module is a simplified version of those described in the first two
types. Typically, modules of this third type lack
mechanical/electrical risers and the integrated vertical shafts
since the modules are intended for random locations within a
building structure where stacking is not a requirement. These
modules require to be individually supported at each floor. As
their name implies, their installation is by sliding over a given
floor until reaching their intended location. A floor cavity or
opening is required, as well as connection to field-installed
mechanical/electrical risers and ventilation ducts or shafts.
Similar to the "drop-in" type, the "slide-in" modules are suitable
for installation in existing buildings being renovated or new
structures in the process of being completed. FIG. 16c illustrates
an exemplary "slide-in" installation type module and method of
installing the building modules according to an embodiment of the
present invention. A structure 186 is built with floor cavities
ready to receive a module 182. The module 282 is lifted to its
destination floor by means of a cradle. The module 282 is slid or
rolled on a bottom module portion 184 into its final position. This
"slide-in" installation method is suitable for use in small
buildings such as single family residences.
[0070] The design of the module of the present invention allows the
floor of the module to be level with the adjacent floor areas. This
is an important comfort feature as well as conforming to U.S. and
international regulations regarding access for the disabled. This
is achieved by lowering the module ceiling with respect to the
adjacent floor structure and lowering the module to module stack
connection at a level below the adjacent floor levels. This allows
clearance for the module floor depth and also for the installation
of air conditioning equipment in the resulting cavity. The design
of the building modules of the present invention also complies with
applicable U.S. and International building codes with regards to
structural, mechanical, electrical, fire-protection, sound
insulation, etc.
[0071] Having disclosed exemplary embodiments, modifications and
variations may be made to the disclosed embodiments while remaining
within the scope of the invention as described by the following
claims.
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