U.S. patent application number 11/005990 was filed with the patent office on 2005-12-01 for modular building construction.
Invention is credited to Allen, Bradford W., Lubin, Stuart.
Application Number | 20050262778 11/005990 |
Document ID | / |
Family ID | 36578575 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050262778 |
Kind Code |
A1 |
Allen, Bradford W. ; et
al. |
December 1, 2005 |
Modular building construction
Abstract
A modular system of construction of loft apartment buildings.
This type of unit is in high demand in many metropolitan areas, and
the modular nature of the inventive buildings allows them to be
produced quickly and at low cost. In addition, the invention
provides a novel system for interconnecting apartments quickly
during construction, providing further cost savings. A mix of
apartment types, including handicapped-accessible apartments, may
be placed in each building, with the proportions of different
apartment types being tailored to the needs of the local market and
the constraints of local building codes. The apartment modules may
be sized to permit convenient shipping of modules within the
constraints of overland shipping regulations.
Inventors: |
Allen, Bradford W.;
(Westwood, MA) ; Lubin, Stuart; (Brookline,
MA) |
Correspondence
Address: |
CHOATE, HALL & STEWART LLP
TWO INTERNATIONAL PLACE
BOSTON
MA
02110
US
|
Family ID: |
36578575 |
Appl. No.: |
11/005990 |
Filed: |
December 7, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11005990 |
Dec 7, 2004 |
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09252635 |
Feb 19, 1999 |
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6826879 |
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Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04B 2001/34892
20130101; E04H 1/04 20130101; E04B 1/34815 20130101 |
Class at
Publication: |
052/079.1 |
International
Class: |
A47K 003/16 |
Claims
What is claimed is:
1. A multiunit building, comprising: multiple connected units, each
unit being formed by two prefabricated modules, a first module
comprising a floor and four wall sections, and a second module
comprising a ceiling and four wall sections, wherein the second
module is stacked vertically atop the first module and connected
thereto; a room of the unit so formed extends from the floor
section of the first module to the ceiling section of the second
module; and a vertical utility chase runs from the floor of the
first module to the ceiling of the second module.
2. The building of claim 1, wherein at least two units are stacked
one atop another, and wherein the vertical utility chase is
continuous between the at least two units.
3. The building of claim 1, wherein at least two units are placed
horizontally adjacent to one another.
4. The building of claim 1, further comprising multiple lobby units
connected to the multiple connected units.
5. The building of claim 4, wherein the multiple lobby units are
vertically stacked and connected by at least one staircase.
6. The building of claim 1, wherein the unit comprises a room
substantially contained within the second module.
7. The building of claim 1, wherein the modules are sized to be
transported on a flatbed truck.
8. A method of building construction, comprising: constructing a
foundation; placing a first module comprising a floor and four wall
sections above the foundation; placing a second module comprising a
ceiling and four wall sections atop the first module; and securing
the second module to the first module to form a building unit,
wherein a room of the unit so formed extends from the floor section
of the first module to the ceiling section of the second module;
and a vertical utility chase extends from the floor of the first
module to the ceiling of the second module.
9. The method of claim 8, further comprising vertically stacking
multiple building units, each unit so stacked comprising a first
module having a floor and four wall sections and a second module
having a ceiling and four wall sections, wherein the vertical
utility chase is continuous between the stacked units and further
comprising connecting a utility feed within the vertical utility
chase.
10. The method of claim 8, further comprising connecting a second
unit horizontally adjacent to the first unit, the second unit
comprising a first module having a floor and four wall sections and
a second module having a ceiling and four wall sections.
11. The method of claim 10, wherein the first unit and the second
unit each comprise a horizontal chase containing at least one
utility feed, and further comprising connecting the utility feed of
the first unit to the utility feed of the second unit.
12. The method of claim 8, wherein the first module and the second
module are constructed in a remote location and transported to the
site of the foundation for placement thereon.
13. A multiunit modular building, comprising: multiple connected
units, each unit comprising a module having a corridor section, a
module comprising a horizontal utility chase section, and a module
comprising a vertical utility chase section, wherein the corridor
sections connect to form an access corridor, the horizontal utility
chase sections connect to form a horizontal utility chase
containing a first utility feed, and the vertical chase sections
connect to form a vertical utility chase containing a second
utility feed.
14. The building of claim 13, wherein at least two units are
stacked one atop another.
15. The building of claim 13, wherein at least two units are placed
horizontally adjacent to one another.
16. The building of claim 13, further comprising multiple lobby
units connected to the multiple connected units.
17. The building of claim 16, wherein the multiple lobby units are
vertically stacked and connected by at least one staircase.
18. The building of claim 17, wherein the vertically stacked lobby
units are connected by at least one vertical chase containing a
utility feed.
19. The building of claim 13, wherein the utility feed is selected
from the group consisting of water pipes, mechanical piping,
electrical wiring, communications and security systems, and life
safety systems.
20. The building of claim 13, wherein the modules are sized to be
transported on a flatbed truck.
21. The building of claim 13, wherein the corridor section and the
horizontal utility chase section are both contained within the same
module.
22. A method of constructing a modular building, comprising:
installing a first unit comprising a first corridor section, a
first horizontal utility chase section, and a first vertical
utility chase section, wherein the first horizontal utility chase
section and the first vertical utility chase section each contain a
utility feed; installing a second unit comprising a second corridor
section, a second horizontal utility chase section, and a second
vertical utility chase section, wherein the second horizontal
utility chase section and the second vertical utility chase section
each contain a utility feed; connecting the units so that the first
corridor section and the second corridor section combine to form an
access corridor, and the first horizontal utility chase and the
second horizontal utility chase combine to form a continuous
utility chase; and connecting the horizontal utility feed of the
first unit and the horizontal utility feed of the second unit for
supply of utility services to the units.
23. The method of claim 22, wherein the utility feeds are selected
from the group consisting of water pipes, mechanical piping,
electrical wiring, communication and security systems, and life
safety systems
24. The method of claim 22, wherein each unit comprises two
vertically stacked modules.
25. The method of claim 22, wherein the first unit and the second
unit are constructed in a remote location and transported to the
site of the building.
26. The method of claim 22, further comprising installing a first
lobby unit comprising a utility chase section containing a lobby
utility feed and connecting the lobby utility feed to the
horizontal utility feed of the first unit.
27. The method of claim 26, further comprising installing a second
lobby unit comprising a utility chase section containing a lobby
utility feed atop the first lobby unit and connecting the lobby
utility feeds of the first and second lobby units via a vertical
utility chase.
28. The method of claim 22, further comprising installing a third
unit comprising a third corridor section, a third horizontal
utility chase section, and a third vertical utility chase section,
wherein the third horizontal utility chase section and the third
vertical utility chase section each contain a utility feed;
connecting the third unit to the first unit so that the first
vertical chase section and the third vertical chase section combine
to form a continuous vertical utility chase; and connecting the
vertical utility feed of the first unit and the vertical utility
feed of the third unit for supply of utility services to the
units.
29. A multiunit modular building, comprising: multiple connected
units, each unit comprising a module having a corridor section and
a module comprising a vertical utility chase section, wherein the
corridor sections connect to form an access corridor, and the
vertical chase sections connect to form a vertical utility chase
containing a utility feed.
30. A method of constructing a modular building, comprising:
installing a first unit comprising a first corridor section and a
first vertical utility chase section, wherein the first vertical
utility chase section contains a first utility feed; installing a
second unit comprising a second corridor section and a second
vertical utility chase section, wherein the second vertical utility
chase section contains a second utility feed; installing a third
unit comprising a third corridor section and a third vertical
utility chase section, wherein the third vertical utility chase
section each contains a third utility feed; connecting the first
and second units so that the first corridor section and the second
corridor section combine to form an access corridor; connecting the
first and third unit sso that the first vertical chase section and
the third vertical chase section combine to form a continuous
vertical utility chase; and connecting the vertical utility feed of
the first unit and the vertical utility feed of the third unit for
supply of utility services to the units.
Description
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 09/252,635, filed Feb. 19, 1999 and issued
Dec. 7, 2004 as U.S. Pat. No. 6,826,879, which is incorporated
herein by reference.
FIELD OR THE INVENTION
[0002] The present application relates to modular systems and
methods for assembling multiunit buildings from multiple vertically
stacked modules, and particularly to systems and methods in which
units may be connected by preformed vertical chases.
BACKGROUND OF THE INVENTION
[0003] Increasing demand for affordable housing in major
metropolitan areas has necessitated the development of creative
systems for housing design. One such solution is the renovation of
underutilized or functionally obsolete buildings, often former
industrial sites, into housing units. One advantage of such units
has been the ability to produce "loft" apartments, in which at
least a portion of each unit has double-height ceilings. These
apartments have become popular in many markets, to the point that
demand for such units may exceed the available supply of buildings
to retrofit. The present invention provides a solution to this
shortage, by providing an affordable system for building such units
from the ground up.
[0004] In addition to the limited supply of buildings suited to be
converted to loft apartments, another major impediment to the
construction of multiunit housing has been the need to provide
adequate parking space for each unit. The present invention also
provides a solution which allows inexpensive modular construction
of living units over an associated parking area, so that a larger
number of apartments may be placed in a given lot while conforming
to local zoning codes and providing adequate parking
facilities.
SUMMARY OF THE INVENTION
[0005] The present invention provides a modular system of
construction of loft apartment buildings. This type of unit is in
high demand in many metropolitan areas, and the modular nature of
the inventive buildings allows them to be produced quickly and at
low cost. In addition, the invention provides a novel system for
interconnecting apartments quickly during construction, providing
further cost savings. A mix of apartment types, including
handicap-accessible apartments, may be placed in each building,
with the proportions of different apartment types being tailored to
the needs of the local market and the constraints of local building
codes. The apartment modules may be sized to permit convenient
shipping of modules within the constraints of overland shipping
regulations.
[0006] In one aspect, the invention comprises a multiunit building
of modular construction, wherein multiple units of the building are
each formed from two prefabricated modules, a lower module
comprising a floor and four wall sections, and an upper module
comprising a ceiling and four wall sections. At least one room of
the unit extends the full height of the unit, i.e., from the floor
of the lower module to the ceiling of the upper module, and a
vertical utility chase extends from the floor of the lower module
to the ceiling of the upper module. The unit may have a mezzanine
level, in which at least one room is substantially contained within
the upper module. The units may be arranged horizontally,
vertically, or both. The building may also comprise lobby units,
which may be vertically stacked and connected by a staircase and/or
an elevator. The modules may be sized to comply with overland
shipping regulations for transportation on a flatbed truck.
[0007] In another aspect, the invention comprises a method of
building construction, comprising installing a foundation, placing
a lower building module above the foundation, placing an upper
building module on the lower module and securing the modules
together. The modules combine to form a building unit, in which at
least one room spans the distance from the floor of the first
module to the ceiling of the second module, and a vertical utility
chase extends from the floor of the lower module to the ceiling of
the upper module. Multiple units may be placed vertically,
horizontally, or both. Horizontally adjacent units may be connected
by a utility feed. The modules may be constructed remotely and
transported to the building site.
[0008] In still another aspect, the invention comprises a multiunit
modular building, wherein horizontally adjacent units are connected
via a corridor and a horizontal utility chase containing a utility
feed, and the units also comprise a vertical utility chase. The
utility feed may include water pipes, mechanical piping, electrical
wiring, communications and security systems, and life safety
systems. The building may further comprise a lobby unit connected
to the building units. Both building units and lobby units may be
vertically stacked, and stacked lobby units may be connected via a
vertical utility chase.
[0009] In yet another aspect, the invention comprises a method of
constructing a modular building comprising installing two units,
each containing a corridor section and a horizontal utility chase
section containing a utility feed, and connecting the units and the
utility feeds. The units also comprise a vertical utility chase.
The utility feeds may include water pipes, mechanical piping,
electrical wiring, communications and security systems, and life
safety systems. The units may each comprise two vertically stacked
modules as described above, and such vertically stacked units may
combine to form a continuous vertical utility chase. The building
may further contain one or more lobby units which may be connected
to the utility feeds, and which may be stacked. Stacked lobby units
may be connected via a vertical utility chase.
BRIEF DESCRIPTION OF THE DRAWING
[0010] The invention is described with reference to the several
figures of the drawing, in which,
[0011] FIG. 1 is a cutaway view of an assembled apartment building
comprising four apartment types according to the invention;
[0012] FIG. 2 is an exploded view of a "base" apartment of the
building of FIG. 1, showing how two modules are stacked to form the
apartment;
[0013] FIG. 3 is a cutaway view of the apartment unit of FIG.
2;
[0014] FIG. 4 is a perspective view of two units as shown in FIG.
2, illustrating corridor access and utility chase connections;
[0015] FIG. 5 is an exploded view of an "intermediate" apartment of
the building of FIG. 1;
[0016] FIG. 6 is a perspective view of two units as shown in FIG.
5, illustrating corridor access and utility chase connections;
[0017] FIGS. 7a-7f are perspective and cutaway views of each unit
as placed in an assembled building;
[0018] FIG. 8 shows a lobby unit for use with the units pictured in
FIG. 5; and
[0019] FIG. 9 shows a multiunit building in which individual units
comprise both horizontal and vertical chases.
DETAILED DESCRIPTION
[0020] The invention is described below with reference to certain
preferred embodiments, in which an assembled apartment building
comprises three types of living units, placed upon a conventional
(nonmodular) semi-depressed parking level. It will be understood by
those skilled in the art that this represents only one embodiment
of the invention, and the invention encompasses many modifications
and variations of the structures described herein. For example, the
number, size, and shape of the living units may be varied over a
wide range, and may include apartments, assisted living units,
hotel rooms or suites, extended stay units, dormitory rooms or
suites, or other types living units. The apartment units need not
all be loft units; in fact, it may be desirable to include some
single-level units in order to comply with handicap-access
regulations. The outer walls of each unit need not be coplanar as
shown below; the invention also contemplates staggered or offset
arrangements of units. Further, the principles of the invention may
be applied to the construction of multiunit office or industrial
buildings, as well as living units. Commercial and dwelling units
may even be mixed in a single building, within the constraints of
local building codes.
[0021] An apartment building according to the invention is
illustrated in cutaway view in FIG. 1, generally as 10. The
building 10 comprises three types of living units: base units 12,
two stories of intermediate units 14, and top units 16. The
illustrated building 10 also comprises a semidepressed parking
level 18. The size and shape of units 12, 14, and 16 may be more
clearly seen in FIG. 7a-7f.
[0022] An exploded view of a base unit 12 is shown in FIG. 2. The
unit comprises a lower module 20 and an upper module 22. Lower
module 20 comprises a floor 24 and four vertical outer walls 26.
Upper module 22 comprises a ceiling 28, four vertical outer walls
30, and a floor section 32. Floor section 32 spans only a portion
of the module. Thus, when the modules are stacked to form the
apartment unit, the unit comprises a great room 34 which has a
floor-to-ceiling height spanning the two modules. Large windows 36
are preferably provided for the great room 34 to further increase
the spacious feeling of the room afforded by the high ceiling. The
rear section 38 of the apartment comprises floor-level rooms having
section 24 as their floor, and mezzanine rooms having section 32 as
their floor. Internal stairs 40 (more clearly seen in FIG. 3, a
cutaway view of the same unit) allow access to the mezzanine level
from the floor level.
[0023] It is preferable that modules 20 and 22 conform to overland
shipping regulations for easy transportation. For example, a module
may have a width not exceeding 14 feet, a length not exceeding 66
feet, and a height not exceeding 11 feet. These sizes are
exemplary, and may be adjusted depending on the method of shipping
used and on local shipping regulations. For example, greater size
flexibility may be afforded when it is practical to ship the units
by barge, ship, or helicopter, or when the modules are constructed
at a location near the building site.
[0024] Access to the unit 12 is afforded by a corridor 42 which
opens onto the mezzanine level. It will be seen that when multiple
units 12 are placed side-by-side to form a building level, the
corridors 42 will connect to form a joint accessway to the
individual apartment units. A pair of units with connected corridor
sections 42 can be seen in FIG. 4.
[0025] Shown adjacent to the corridor 42 is a horizontal chase 44
whereby building services such as water pipes, electrical wiring,
communications and security systems, and sprinkler and other life
safety systems (not shown) may be provided. It is an advantage of
this type of building module that access to water pipes and the
like may be provided by an access panel (not shown) on the common
corridor 42, removing the necessity for workmen to enter individual
apartments when performing maintenance.
[0026] It is a further advantage of the horizontal chase 44 that it
facilitates easy connection of building services such as water and
electricity. Pipes and wiring may be preinstalled in the chase when
the unit is constructed, so that they need only be "plugged in" to
an adjacent unit 12 when the building is assembled on-site. The
prior art almost exclusively uses vertical chases for these
services, so that pipes and wires must be fed through the chase by
hand after the building is assembled.
[0027] The ease of connection of the building services also
facilitates on-site "finishing" of the apartment unit. In this
concept of building construction, module 22 is stacked atop module
20, and chase utility feed connections to the previously installed
adjacent unit are immediately made. The newly installed unit 12 is
then immediately powered, and workmen can simply turn on the
preinstalled lights and plug power tools into existing wall outlets
in order to finish securing the modules together and to the
adjacent unit, and to install cosmetic elements such as molding to
cover the module joints. In addition, construction site security
can be maintained by immediate connectivity to a central security
monitor specifically equipped for temporary duty on the active
construction sites. Sprinkler systems can be activated far in
advance of conventional construction methods, reducing the risk of
damage by fire.
[0028] A second type of unit 14 is illustrated in FIG. 5. The
modules 46 and 48 making up the unit 14 are of approximately the
same size and shape as modules 20 and 22, but they combine to form
different apartment shapes. The apartments does not stretch across
the full width of the building 10 as does unit 12; instead, each
apartment is approximately one-half the length and twice the width
of unit 12, and separate apartments are placed on opposite sides of
the corridor 50. The units on either side of the corridor need not
be identical in space or layout, if it is desired to have a
building with a variety of apartment configurations. In order to
provide utility feeds for apartments on either side of the corridor
50 in this configuration, it is preferable to place the horizontal
utility chase 52 under (as shown) or over the corridor 50. Access
panels may be placed in the floor (or ceiling) corridor 50 if
desired, but it will generally be found preferable to access the
utility chase 52 from inside the apartment units in this
configuration. FIG. 6 is a perspective view of two assembled units
14, with corridor 50 and utility chase 52 connections extended for
clarity.
[0029] A third type of unit 16 for placement on the top level of
the building 10 is shown in FIGS. 7e and 7f. As pictured, this unit
comprises three modules and is three times the width of unit 12. It
will be apparent to those skilled in the art that other unit shapes
and sizes may also be used. As shown, unit 12 is a single-level
unit (which may be made handicap-accessible if desired), but the
top unit may also have a mezzanine if preferred. The modules making
up this unit preferably comprise integral membrane roofing and roof
drains, and may further comprise skylights, coffered ceilings,
clerestories or the like to enhance the perception of light and
space in the units. Unit 16 comprises horizontal chases, as do the
other units 12 and 14, for rapid connection of adjacent units.
[0030] Buildings according to the invention are extremely
economical in space usage. For example, in a preferred embodiment,
the height X of units 12 and 14 may be 18 feet. The height Y of
units 16 may be 10.5 feet, and the elevation of ground floor units
12 above the grade Z may be 5.5 feet, for a total building height
of 70 feet. This configuration falls within the Building Officials
and Code Administrators (BOCA) International standard for Type 3A
construction of a multi-family, fully sprinklered building.
(Because mezzanine areas are limited to _the area below them under
the BOCA definitions, the pictured unit is considered a four-story
building, and falls within the five story limit for a building of
this type. Because the standard allows a five story building of
this height, it may be desirable for the upper levels in one floor
of apartments to be expanded, offering greater flexibility in
apartment design).
[0031] At least one vertical chase 54 is provided for the building
in order to connect the daisy-chained horizontal chases of each
level of the building to a central utility feed. This vertical
chase may run parallel to an elevator shaft 56, for example, in
order to provide further space savings. FIG. 8 shows a modular unit
for a lobby area, from which two rows of units 14 may extend.
(While the pictured unit is configured for connection with unit
type 14, it will be apparent to those skilled in the art that lobby
units for connections to unit types 12 and 16 can easily be
constructed). Apertures 58 are provided for connection with the
corridor 50, and apertures 60 are provided for connection with the
horizontal chase 52. The lobby further comprises emergency stairs
62.
[0032] Vertical chases may also be provided for the individual
units. When such chases are combined with the horizontal chases
described above, a "network" of utility feeds can be created. Such
a network may be useful when a communications network is to be
installed in the building, or when it is desired to bring certain
services up from a central system in the basement or roof, while
other service feeds come from systems in the lobbies or elsewhere.
For example, water pipes and HVAC ducts might run vertically from
the basement and roof, respectively, while electrical wires run
horizontally from vertical trunk cables. Alternatively, all
services may be provided via the vertical chases, which may still
be configured to allow corridor access.
[0033] A configuration showing both vertical and horizontal chases
within the living units is shown in FIG. 9. As shown, each unit
comprises a section of a horizontal chase 44 and a vertical chase
64. These chases adjoin at junction 66, forming a three-dimensional
"network" of utility feeds. As shown, the vertical chases 64 adjoin
corridor 42, so that they may be accessed by service personnel from
outside the living unit.
[0034] The length of base units 12 is preferably somewhat longer
than that of the upper modules. This additional length ensures an
interior width inside the foundation walls suitable for ease of
parking and maneuvering, and serves as a basis for articulating the
architectural base of a building constructed according to the
invention. The extra length further serves continuous,
uninterrupted bearing walls for the units above.
[0035] All units 12, 14, 16 are preferably constructed with
"hard-shell integrity," allowing improved fire safety and sound
deadening (high STC for residential construction). The integral
roof construction of the top units 16 means that any roof failure
is localized and the possibility of collateral or residual damage
is minimized.
[0036] The buildings of the invention can be constructed extremely
rapidly. An exemplary 96-unit building in the configuration shown
in FIG. 1, for example, may be constructed in a period of about 16
weeks. Preferably, construction begins with laying of the building
foundation and construction of the semidepressed parking structure,
if included. A column of level lobbies, containing the elevator
shaft and vertical utility feed is then constructed, and building
units can then be placed in one or more wings extending from the
lobby area. It will generally be found preferable to add modules to
the building in stacks, placing all levels over a given base unit
12 before placing the next base unit, but construction may also
proceed by placing all ground level units, followed by all second
level units, etc.
[0037] It will generally be preferable for modules to be finished
as much as possible in the factory, before shipping to the building
site. This is facilitated by the horizontal chase structure which
allows utility feeds to be placed in the chase during
manufacturing, so that only splices between units need be completed
in the field. The attachment of the lower module 20 to the upper
module 22 must be accomplished in the field, but much of the
initial machining (e.g., drilling holes, providing quick-connect
fittings for ductwork and plumbing) may be accomplished at the
factory, and all necessary hardware may be placed in one of the
modules during the manufacturing process, allowing quick and easy
connection of the modules. Carpeting, windows, etc. may all be
preinstalled at the factory, allowing improved working conditions
for installation personnel and lower costs for the
manufacturer.
[0038] Other embodiments of the invention will be apparent to those
skilled in the art from a consideration of the specification or
practice of the invention disclosed herein. It is intended that the
specification and examples be considered as exemplary only, with
the true scope and spirit of the invention being indicated by the
following claims.
* * * * *