U.S. patent application number 13/102178 was filed with the patent office on 2012-11-08 for modular building system and method.
This patent application is currently assigned to EPSILON INDUSTRIES INC.. Invention is credited to Darryl Gillespie, Bruce Johnston, Steve McAllister, Chris Wiederick.
Application Number | 20120279141 13/102178 |
Document ID | / |
Family ID | 47089266 |
Filed Date | 2012-11-08 |
United States Patent
Application |
20120279141 |
Kind Code |
A1 |
Wiederick; Chris ; et
al. |
November 8, 2012 |
MODULAR BUILDING SYSTEM AND METHOD
Abstract
A modular building unit for use in constructing a building
comprises a top, a base, two opposed ends and at least one open
side. The at least one open side extends between the two opposed
ends and is free of upwardly extending structural supports. The
modular building unit is configured to be interconnected to a
second modular building unit along the at least one open side. The
building unit is dimensioned to enable the building unit to be
accommodated at or within a predetermined width limit for
transportation before assembly and the building unit and the second
modular building unit, when assembled, exceeding the predetermined
width limit.
Inventors: |
Wiederick; Chris; (Kingston,
CA) ; Gillespie; Darryl; (Kingston, CA) ;
McAllister; Steve; (Amherstview, CA) ; Johnston;
Bruce; (Hartington, CA) |
Assignee: |
EPSILON INDUSTRIES INC.
Kingston
CA
|
Family ID: |
47089266 |
Appl. No.: |
13/102178 |
Filed: |
May 6, 2011 |
Current U.S.
Class: |
52/79.5 ;
52/745.02 |
Current CPC
Class: |
E04B 1/3483 20130101;
E04H 5/02 20130101; E04H 2005/005 20130101 |
Class at
Publication: |
52/79.5 ;
52/745.02 |
International
Class: |
E04H 1/00 20060101
E04H001/00; E04G 21/14 20060101 E04G021/14 |
Claims
1. A modular building unit for use in constructing a building
comprising: a top, a base, two opposed ends and at least one open
side, the at least one open side extending between the two opposed
ends and being substantially free of structural supports; the
modular building unit being configured to be interconnected to a
second modular building unit along the at least one open side; and
the building unit being dimensioned to enable the building unit to
be accommodated at or within a predetermined width limit for
transportation before assembly and the building unit and the second
modular building unit, when assembled, exceeding the predetermined
width limit.
2. The modular building unit of claim 1 wherein the building unit
comprises at least one roof truss interconnecting the top and the
two opposed ends.
3. The modular building unit of claim 2 wherein the at least one
roof truss comprises a plurality of roof trusses.
4. The modular building unit of claim 1 further comprising at least
one base truss interconnecting the base and the two opposed
ends.
5. The modular building of claim 4 wherein the at least one base
truss comprises a plurality of base trusses.
6. The modular building unit of claim 2 further comprising at least
one base truss interconnecting the base and the two opposed
ends.
7. The modular building of claim 6 wherein the at least one base
truss comprises a plurality of base trusses.
8. The modular building unit of claim 7 further comprising fixtures
along the sides, adjacent the sides, for attaching lines for
lifting the modular building unit.
9. The modular building unit of claim 7 wherein the roof trusses
and the base trusses comprise substantially flat trusses.
10. The modular building unit of claim 8 wherein the roof trusses
and the base trusses are spaced to prevent deformation of the
modular building unit when lifted by the lines.
11. A white space for computer equipment comprising a plurality of
modular building units according to claim 1.
12. The modular building unit of claim 11 further comprising
computer hardware racks mounted to the base.
13. The modular building unit of claim 1 wherein the opposed ends
comprise walls.
14. The modular building unit of claim 13 wherein the at least one
open side comprises at least one of internal flanges and external
flanges for interconnecting the modular building unit to the second
modular building unit.
15. The modular building unit of claim 7 further comprising floor
tiles covering the base trusses.
16. The modular building unit of claim 15 wherein the base trusses
comprise openings for at least one of an in-floor air distribution
system, an in-floor electrical distribution system and an in-floor
mechanical distribution system.
17. The modular building unit of claim 3 wherein the roof trusses
are positioned to accommodate at least one of an air distribution
system, an electrical distribution system and a mechanical
distribution system.
18. A modular system for construction of a building comprising: two
end building units comprising a roof, a base, two opposed ends and
one open side; the building units being configured to be
interconnect along the open sides, the open sides of the building
units being substantially free of upright structural supports; the
building units being dimensioned to enable the building units to
accommodated at or within a predetermined width limit for
transportation before assembly and the building, when assembled,
exceeding the predetermined width limit.
19. The modular system of claim 18 further comprising at least one
intermediate building unit comprising a roof, a base, two opposed
ends and two open sides, the at least one intermediate building
unit being located between the two end building units.
20. The modular system of claim 18 wherein the at least one
intermediate building unit comprises a plurality of intermediate
building units.
21. A method of constructing a building comprising: providing a
plurality of modular building units, each of the building units
comprising: a roof, a base, two opposed ends and at least one open
side, the at least one substantially open side extending between
the two opposed ends and being free of structural supports; the
modular building units being configured to be interconnected to
others of the modular building units along the at least one open
side; the building units being dimensioned to enable the building
units to be accommodated at or within a predetermined width limit
for transportation before assembly and the building unit and the
second modular building unit, when assembled, exceeding the
predetermined width limit; transporting the plurality of modular
building units to a building site; successively positioning the
modular building units side-by-side; interconnecting the modular
building units.
Description
FIELD
[0001] The following relates to a modular building system and
method. The system includes modular units that may be constructed
at a manufacturing facility and then be transported to a
construction site for assembly.
BACKGROUND
[0002] The power plants and computer rooms of buildings are often
large and complex systems with a large amount of interconnected
equipment. These systems can be incorporated into a main building.
However, it may be advantageous to house such facilities in a
separate building. This allows the main building to be reserved for
other uses and allows easier access to the equipment in the
separate building.
[0003] The complexity of the systems also means that it may be
advantageous to assemble, interconnect and test the equipment in a
manufacturing facility and then ship the completed system to the
construction site. One way this has been done is to use a shipping
container as a building in which to assemble the equipment. The
equipment is assembled and tested and then shipped to the
construction site to be interconnected to the main building.
[0004] A limitation on this approach is the size of a standard
shipping container. A standard shipping container may be
8'.times.8'.times.40'. If the equipment to be assembled requires
more space, a second shipping container is used. The result is that
that the equipment is housed in a number of different
8'.times.8'.times.40' building. This limits accessibility to
installed equipment, limits the type of cooling system that can be
used, and is unattractive.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present invention, there is
provided a modular building unit for use in constructing a building
comprising: a top, a base, two opposed ends and at least one open
side, the at least one open side extending between the two opposed
ends and being substantially free of structural supports; the
modular building unit being configured to be interconnected to a
second modular building unit along the at least one open side; and
the building unit being dimensioned to enable the building unit to
be accommodated at or within a predetermined width limit for
transportation before assembly and the building unit and the second
modular building unit, when assembled, exceeding the predetermined
width limit.
[0006] In some embodiments the building unit comprises at least one
roof truss interconnecting the top and the two opposed ends.
[0007] In some embodiments the at least one roof truss comprises a
plurality of roof trusses.
[0008] In some embodiments the modular building unit comprises at
least one base truss interconnecting the base and the two opposed
ends.
[0009] In some embodiments the at least one base truss comprises a
plurality of base trusses.
[0010] In some embodiments the modular building unit comprises
fixtures along the sides, adjacent the sides, for attaching lines
for lifting the modular building unit.
[0011] In some embodiments the roof trusses and the base trusses
comprise substantially flat trusses.
[0012] In some embodiments the roof trusses and the base trusses
are spaced to prevent deformation of the modular building unit when
lifted by the lines.
[0013] In some embodiments a white space for computer equipment
comprises a plurality of modular building units.
[0014] In some embodiments the modular building unit comprises
computer hardware racks mounted to the base.
[0015] In some embodiments the opposed ends comprise walls.
[0016] In some embodiments at least one open side comprises at
least one of internal flanges and external flanges for
interconnecting the modular building unit to the second modular
building unit.
[0017] In some embodiments the modular building unit comprises
floor tiles covering the base trusses.
[0018] In some embodiments the base trusses comprise openings for
at least one of an in-floor air distribution system, an in-floor
electrical distribution system and an in-floor mechanical
distribution system.
[0019] In some embodiments the roof trusses are positioned to
accommodate at least one of an air distribution system, an
electrical distribution system and a mechanical distribution
system.
[0020] According to another aspect of the present invention, there
is provided a modular system for construction of a building
comprising: two end building units comprising a roof, a base, two
opposed ends and one open side; the building units being configured
to be interconnect along the open sides, the open sides of the
building units being substantially free of upright structural
supports; the building units being dimensioned to enable the
building units to accommodated at or within a predetermined width
limit for transportation before assembly and the building, when
assembled, exceeding the predetermined width limit.
[0021] In some embodiments the modular system further comprises at
least one intermediate building unit comprising a roof, a base, two
opposed ends and two open sides, the at least one intermediate
building unit being located between the two end building units.
[0022] In some embodiments the at least one intermediate building
unit comprises a plurality of intermediate building units.
[0023] According to still another aspect of the present invention,
there is provided a method of constructing a building comprising:
providing a plurality of modular building units, each of the
building units comprising: a roof, a base, two opposed ends and at
least one open side, the at least one substantially open side
extending between the two opposed ends and being free of structural
supports; the modular building units being configured to be
interconnected to others of the modular building units along the at
least one open side; the building units being dimensioned to enable
the building units to be accommodated at or within a predetermined
width limit for transportation before assembly and the building
unit and the second modular building unit, when assembled,
exceeding the predetermined width limit; transporting the plurality
of modular building units to a building site; successively
positioning the modular building units side-by-side;
interconnecting the modular building units.
[0024] Other aspects and features of the present invention will
become apparent, to those ordinarily skilled in the art, upon
review of the following description of the specific embodiments of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will now be described in greater detail with
reference to the accompanying drawings, in which:
[0026] FIG. 1A is a perspective view of a first end modular
building unit;
[0027] FIG. 1B is a perspective view of the opposite side of the
modular building unit of FIG. 1A;
[0028] FIG. 1C is a perspective view of the modular building unit
of FIG. 1A with the walls, base trusses and base cover plate
omitted;
[0029] FIG. 2A is a perspective view of an intermediate modular
building unit;
[0030] FIG. 2B is a perspective view of the modular building unit
of FIG. 2A with the walls, base trusses and base cover plate
omitted;
[0031] FIG. 3A is a perspective view of a second end modular
building unit;
[0032] FIG. 3B is a perspective view of the opposite side of the
modular building unit of FIG. 3A;
[0033] FIG. 3C is a perspective view of the modular building unit
of FIG. 3A with the walls, base trusses and base cover plate
omitted;
[0034] FIG. 4A is a side view of the intermediate modular building
unit of FIG. 2A with support rigging;
[0035] FIG. 4B is an end view of the modular building unit with
support rigging of FIG. 4A;
[0036] FIG. 4C is a perspective view of the modular building unit
with support rigging of FIG. 4A;
[0037] FIG. 5A is a side view of a mechanical plant modular
building unit with support rigging;
[0038] FIG. 5B is an end view of the mechanical plant modular
building unit with support rigging of FIG. 5A;
[0039] FIG. 5C is a perspective view of the mechanical plant
modular building unit with support rigging of FIG. 5A;
[0040] FIG. 6 is a perspective view of the positioning of a second
mechanical plant modular building unit;
[0041] FIG. 7 is a perspective view of the positioning of the
mechanical plant modular building unit and support rigging of FIGS.
5A-5C with the modular building unit of FIG. 6;
[0042] FIG. 8 is a perspective view of the positioning of the
modular building unit of FIGS. 1A-1C with the modular building
units of FIG. 7;
[0043] FIG. 9 is a perspective view of the positioning of the
modular building unit of FIGS. 2A-2B with the modular building
units of FIG. 8;
[0044] FIG. 10 is a perspective view of the positioning of a the
modular building unit of FIGS. 3A-3C with the modular building
units of FIG. 9;
[0045] FIG. 11 is a perspective view of the assembled modular
building;
[0046] FIG. 12 is a schematic perspective view of the joining of
the modular building units;
[0047] FIG. 13 is a schematic cross-sectional view of the placement
of the long roof joining strips;
[0048] FIG. 14 is a schematic cross-sectional view of the placement
of the roof seam joining strips;
[0049] FIG. 15 is a schematic cross-sectional view of the placement
of the wall joining strips;
[0050] FIG. 16 is a schematic cross-sectional view of the internal
unit joints;
[0051] FIG. 17 is a perspective view of the assembled modular
building of FIG. 11 with a cooling tower; and
[0052] FIG. 18 is a perspective view of the assembled modular
building with the cooling tower of FIG. 17 with the exterior shown
as wire frame.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0053] FIGS. 1A-1C, 2A-2B and 3A-3C show modular building units.
FIGS. 1A-1C show a first side unit 8, FIGS. 2A-2C show an
intermediate unit 10, and FIGS. 3A-3C show a second side unit 12.
The units 8, 10 and 12 may be used, for example, for the
construction of a modular computer room. In FIGS. 1A-1C, 2A-2B and
3A-3C, the same reference characters are used to identify the same
features. The differences between the units 8, 10 and 12 will be
identified.
[0054] The units 8, 10 and 12 have a base 14, a roof 16 and two
opposed end walls 18. The first side unit 8 also has a first side
wall 20. The second side unit 12 also has a second side wall 22. In
FIGS. 1C, 2B and 3C, the units 8, 10 and 12 are shown without
walls, roofs, floor plates and floor trusses for ease of viewing
internal features.
[0055] As noted above, the units 8, 10 and 12 include a base 14. In
the present embodiment, the base 14 is formed with a frame 24
(FIGS. 1C, 2B and 3C). The frame 24 defines a rectangular perimeter
of the base 14. The frame 24 of the present embodiment is attached
to beams 26, plates 28 and braces 30. The base 14 is formed of
alternating the beams 26 with the plates 28. The braces 30 of this
embodiment extend perpendicular to the beams 26 and provide support
between the beams 26. In this embodiment, the plates 28 may be
formed of eight inch thick sheet steel. Other embodiments may use
different materials and more, fewer or no plates 28. Similarly, the
number location and orientation of the beams 26 and the braces 30
may be varied or eliminated depending on the weight and strength
requirements for the base 14. For example, the base 14 may be
formed of a single plate or of an open lattice of beams. All or
part of the perimeter frame 24 may also be eliminated.
[0056] In this embodiment, the base 14 is rectangular with short
opposed ends 32. End posts 34 are provided at the four corners of
the base 14 along the opposed ends 32. Two end posts 34 are also
located at an intermediate position along the opposed ends 32. The
end posts 34 of the present embodiment are upright posts which
extend from the base 14 to the top which has the roof 16. The end
posts 34 may be, for example, welded or bolted to the base 14. The
tops of the end posts 34 are connected to end roof members 36. The
end roof members 36 of this embodiment extends horizontally above
the opposed ends 32 and define the ends of the roof 16.
[0057] In this embodiment, the intermediate unit 10 of FIGS. 2A and
2B has two sides 38. The sides 38 are opposite and are open. The
sides 38 are open in that there are no walls, posts or other
supports extending across the sides 38. In contrast, the first side
unit 8 has an open side 38 and a first side wall 20 and the second
side unit 12 has an open side 38 and a second side wall 22.
[0058] Side roof members 40 extend along the un-open sides of the
first and second end units 8 and 12 and connect to the top of the
corner end posts 34 of the side walls 20 and 22. The un-open sides
have side posts 42 behind the first side wall 20 and the second
side wall 22. In this embodiment, the side posts 42 are upright and
extend from the base 12 to side roof members 40. In the second side
unit 12, two of the side posts 42 also define a door opening
44.
[0059] The general framing described in respect of this embodiment
is exemplary only. Other framing that includes differing structure
such as diagonal side and end members may also be used. The posts
may also be eliminated if structured strength is provided by the
walls.
[0060] In this embodiment, the units 8, 10 and 12 have lengthwise
roof trusses 46, crosswise roof trusses 48 and lengthwise base
trusses 50. The lengthwise roof trusses 46 extend between the
opposed ends 32 are connected to the end posts 34. In this
embodiment, the roof trusses 46 comprise a continuous unit. The
crosswise roof trusses 48 are pairs of trusses that are connected
between the lengthwise roof trusses 46 at right angles.
[0061] In this embodiment, the units 8, 10 and 12 all have a pair
of crosswise roof trusses 48 extending parallel to and intermediate
the opposed ends 32. The intermediate unit 10 has three lengthwise
roof trusses 46 extending between the tops of the opposite end
posts 32. The three lengthwise roof trusses 46 are connected at
their intermediate peak by the pair of crosswise roof trusses 48.
The end units 8 and 12 have a similar configuration but do not have
lengthwise roof trusses 22 along their walls 20 and 22
respectively.
[0062] The base trusses 50 are shown in FIGS. 1B, 2A, 3A and 3B. In
this embodiment, the base 14 is covered with sections of plate 52.
The sections of plate 52 may be sheets of checkerboard steel plate
connected to the beams 26. The base trusses 50 extend from end to
end and connect between the opposed ends 32 and may connect to
braces 33 and end walls 18. The base trusses 50 of this embodiment
are parallel to the open sides 38 and the side walls 20 and 22.
[0063] In this embodiment, the lengthwise roof trusses 46 are flat
bottomed and are peaked on top to follow the roof line. The
crosswise roof trusses 48 and the base trusses 50 are flat on top
and bottom. The trusses 46, 48 and 50 have triangular positioned
struts angled at 60.degree. to each other. In this embodiment, the
roof trusses 22 are spaced at six foot intervals parallel to the
open sides 38 and the base trusses 50 are spaced at two foot
intervals, also parallel to the open sides 38. The roof trusses 46
and 48 of this embodiment may have a height of approximately 20
inches and the base trusses 50 of this embodiment may have a height
of approximately 8 inches. In this embodiment, the base trusses 50
may incorporate rectangular openings 54 to allow piping or other
conduits to extend through the base trusses 50 under the floor
plate 52.
[0064] The truss designs and layouts described above are exemplary
only. Numerous truss designs and layouts exist that which performed
the required function of allowing the units 8, 10 and 12 to be
constructed and transported with open sides 38. In some
embodiments, some or all of the trusses 46, 48 and 50 may be
altered or eliminated. Any truss design and positioning that
supports the modular building units 8, 10 and 12 for transport and
installation with open sides 38 at least substantially open may be
used. Designs that include some members extending across the open
sides 38, such as braces in the upper corners, are also
contemplated by the invention.
[0065] The connection of the members may be made by known means.
For example, the end posts 34 may be, welded or bolted to the base
14. The end walls 18 may be connected to the end posts 34, for
example, by welding, bolting or by being wrapped around the corner
end posts 34. The end walls 18 may, for example, be formed of
corrugated metal such as corrugated steel. Other embodiments may
not be rectangular and may, for example, be rounded or irregular in
shape.
[0066] FIGS. 4A, 4B and 4C are side, end and perspective views,
respectively, of the modular building unit 10 with rigging 60 for
lifting the unit 10. The lifting and positioning of the unit 10
will be described with reference to FIGS. 4A, 4B and 4C.
[0067] As noted above, the unit 10 comprises a base 14 with a frame
24. The frame 24 of this embodiment includes side faces 62. Spaced
along the side faces 62 are lifting points 64. In this embodiment,
there are four lifting points 64 spaced along the side faces 62 of
the two open sides 38. The lifting points 64 are pairs of angled
plates with a hole 66 there through that are connected to the base
14 and angled towards each other at an approximately 45.degree.
angle. The lifting points 64 may be of a different number and
configuration such as eye bolts. They may be differently
positioned, for example on the base 14, posts 34 or roof 16. They
may also be eliminated and a different lifting means used.
[0068] FIGS. 4A to 4C also show rigging 60. The rigging 60 is not
part of the modular building unit 10. The rigging 60 may be
attached to the modular building unit 10 to allow the modular
building unit 10 to be lifted and moved by, for example, a crane.
The modular building unit 10 can thus be loaded on a truck for
transportation to an assembly location and then lifted off of the
truck and positioned for assembly.
[0069] The rigging 60 of this embodiment includes two pairs of
straps or lower lines 68 for connection to each of the lifting
points 64 through the holes 66. In some embodiments, the pairs of
lifting points 64 are positioned to give an approximately
60.degree. angle between each of the lower lines 68 and the base
14. The lower lines 68 are collected by pulleys 70 to cross-members
72. The cross-members 72 connect to the pulleys 70 on opposite
sides 38 of the modular building unit 10. The ends of the
cross-members 72 are in turn connected to pairs of upper lines 74.
The upper lines 74 from each of the cross-member 72 meet at ends of
an upper member 76. The rigging 60 is symmetrical to allow a
balanced load support for the modular building unit 10.
[0070] FIGS. 5A to 5C show a mechanical plant modular building unit
80 that may be used with the modular building units of FIGS. 1A to
4C in forming a modular building. The mechanical plant unit 80 may
be used to house a mechanical section of the building that includes
equipment that heats and cools the building. In this embodiment,
the modular building unit 80 includes a base 82, end walls 84, a
roof 86, upright posts 88 and two sides 90. The modular building
unit 80 may have the same basic materials and outer shape as the
modular building unit 10. However, the modular building unit 80 of
this embodiment does not include any trusses and the sides 90 are
not open. Instead, the sides 90 include a series of four support
posts 91 along the sides 90. The modular building unit 80 of this
embodiment also includes mechanical plant equipment 92. The number
and positioning of the support posts 91 will depend on the weight
and weight distribution of the mechanical plant equipment 92.
[0071] In this embodiment, the modular building unit 80 has lifting
points 94. The lifting points 94 of the modular building unit 80
are on the roof 86 rather than the base 82, in contrast to the
positioning of the lifting points 64 on the modular building unit
10. In this embodiments, there are eight lifting points 94 each
having a hole there through. Four of the lifting points 94 are
vertically aligned with the top of four of the upright posts 88 and
four of the lifting points 94 are vertically aligned with the top
of four of the support posts 91. The upright posts 88 and the
support posts 91 may provide rigidity to prevent deformation of the
modular building unit 80 when lifted by the lifting points 94.
[0072] FIGS. 5A to 5C also depict a rigging 100 which is not part
of the modular building unit 80 but which may be used to lift the
modular building unit 80 with, for example, a crane. The rigging
100 of this embodiment may include fours straps or lines 102
connected to the holes 96 of the lifting points 94. The lines 102
are connected through four pulleys 106 to a lengthwise beam 108.
The arrangement and attachment of the rigging 100 of the present
embodiment is symmetrical both lengthwise and width-wise to the
modular building unit 80.
[0073] The shape and structure of the modular building unit 80 may
be altered, include trusses, have different attachment points for
rigging and may include different equipment. The modular building
unit 80 may also be eliminated.
[0074] FIGS. 6 to 10 schematically show how a modular building can
be constructed using the modular building units of FIGS. 1 to
5C.
[0075] FIG. 6 shows a second mechanical plant modular building unit
110. The unit 110 may be similar in construction to the modular
building unit 80 of FIGS. 5A to 5C but may contain different
equipment than the modular building unit 80 such that the equipment
in the two modular building units 80 and 110 may be connectable and
may together comprise the equipment for a mechanical plant for a
modular building. The unit 110 may we lifted and positioned using
the same rigging 100 as used for the modular building unit 80.
[0076] FIG. 7 shows the modular building unit 110 positioned and
the rigging 100 removed. The rigging 100 is attached to the modular
building unit 80 which is being moved with the aid of the rigging
100 to be positioned next to the modular building unit 110.
[0077] FIG. 8 shows the modular building units 110 and 80
positioned and the rigging 100 removed. FIG. 8 also shows the first
end unit 8. The rigging 60 used to lift and position the modular
building unit 10 may also be used to lift and position the first
end unit 8.
[0078] FIG. 9 shows the modular building units 110, 80 and 8
positioned next to each other with sides of their bases, their end
walls and their roofs aligned. There is no rigging attached to the
modular building units 110, 80 and 8 as they are in their installed
positions. The rigging 60 is attached to the intermediate unit 10
which in being moved into position aligned with the first end unit
8.
[0079] FIG. 10 shows the modular building units 110, 80, 8, and 10
positioned next to each other with sides of their bases, their end
walls and their roofs aligned. There is no rigging attached to the
modular building units 110, 80, 8 and 10 as they are in their
installed positions. The rigging 60 is attached to a second end
unit 12 which in being moved into position aligned with the modular
building unit 10.
[0080] FIG. 11 shows the five modular building units 110, 80, 8, 10
and 12 aligned in position next to each other to form a modular
building 112. It will be appreciated that the modular building
units 110 and 80, which have upright support posts along the side
walls and no trusses, may be eliminated. In this embodiment, the
modular building units 8, 10 and 12 include base and roof trusses
which allow the sides of the modular building units 8, 10 and 12
which face each other to be free of any supports or other elements
that block the sides. This allows a large open room to be formed by
the modular building units 8, 10 and 12 which can be used to house
computer equipment and racks and which can be transported without
any reinforcement of the open sides 38.
[0081] In other embodiments, more or fewer modular building units
with at least one open side may be used. For example, any number of
building units from one to tens or more with two open sides, such
as modular building unit 10 may be used to make any size of
building. Alternatively, modular building unit 10 may be eliminated
and modular building units 8 and 12, with facing open sides, may be
used to provide a smaller open room.
[0082] FIGS. 11 to 16 show various details of how the modular
building units 110, 80, 8, 10 and 12 may be joined and sealed to
each other. It will be appreciated that these are only exemplary
joining and sealing means. Other joining and sealing means know in
the art may be used.
[0083] FIG. 12 shows two portions 114 of a modular building unit.
The portions 114 each have an upwardly extending L-shaped flange
116 along the inwardly facing roof edges. There are also inwardly
extending flanges 118 along the inside edges of the facing sides.
The inwardly extending flanges 118 may include pairs of facing unit
joining clips 120. For assembly, this embodiment also includes roof
joining strips 122 and wall joining strips 124.
[0084] The joining of the walls of the two portions 114 of the
modular building unit is shown in FIG. 13. Three caulking beads 126
are applied along the back of the wall joining strip 124. The wall
joining strip 124 is aligned over the seam formed by the mating
edges of the two portions 114. The wall joining strip 124 is then
screwed into place by screws 128 extending through the wall joining
strip 124 and into the walls of the portions 114.
[0085] The joining of the roofs of the two portions 114 of the
modular building unit is shown in FIG. 14. Three caulking beads 126
are applied along the back of the roof joining strip 122. The roof
joining strip 122 is aligned over the mating horizontal portions of
the L-shaped flanges 116 of the two portions 114. The roof joining
strip 122 is then screwed into place by screws 128 extending
through the roof joining strip 122 and into the L-shaped flanges
116.
[0086] In this embodiment, an additional seal is used where the
peak of the roofs join. FIG. 15 shows a long roof peak joining
strip 130 that is positioned over the seam where the roof peaks of
the modular building units 110, 80, 8, 10 and 12 join (see FIG.
11). As with the joining strips 122 and 124 (see FIG. 11), the long
roof peak joining strips 130 first have three beads of caulking 126
applied. The long roof peak joining strips 130 are then screwed
into position by the screws 128 into the two portions 114.
[0087] The final fastening elements of this embodiment are the unit
joining clips 120. As shown in FIG. 16, these unit joining clips
120 can be connected by a threaded rod 132 extending through
aligned holes in the unit joining clips 120 and secured by nuts
134.
[0088] Some or all of these joining means may be altered or
eliminated. For example, it will be appreciated that the weight of
the units may prevent their relative movement and caulking or other
weather sealing of the seams between the units may be
sufficient.
[0089] FIGS. 17 shows the modular building 112 completely installed
with a cooling tower and associated walkway 136 installed. FIGS. 18
shows the same view of the modular building 112 as FIG. 17 but with
the exterior shown as wire frame so that the interior components
are visible. The large room created by the units 8, 10 and 12 is
filled with computer racks 138 which may be fastened to a floor
140.
[0090] In embodiments which include the base trusses 50, the base
trusses 50 may be are covered by the floor 140. The floor may be
assembled to the modular building unit 10 either at the factory or
at the end location. The floor 140 may be a computer room raised
floor tile. An in-floor air distribution system may be installed
under the floor 140, between and/or through the trusses 50.
Electrical, air distribution and mechanical distribution systems
may be run in either or both of the base and roof truss systems.
Conduits, both for water and electrical or other functions may be
run between the floor 140 and the base 12 in the space created by
the trusses 24 through the openings 54.
[0091] In some embodiments computer equipment 138 racks are
installed to the floor at the factory and the modular building
units 8, 10 and 12 are transported with both the floor and computer
equipment racks in place to further reduce the assembly required
with the modular building units 10 are installed at their final
destination. As can be seen in FIG. 18, the absence of supports on
the open sides 38 of the modular building units 8, 10 and 12 allows
the computer equipment to be installed where required without
maneuvering around support posts. Supports may be included angled
at the base or roof, or upright adjacent the ends to provide some
support while still leaving the sides 38 substantially open and
able to accommodate, for example computer racks, without negatively
affecting the layout.
[0092] In some embodiments, the modular building units 8, 10 and 12
are 30 to 50 feet long, 10 to 20 feet wide and 8 to 12 feet high.
The width and length of the modular building units 8, 10, 12, 80
and 110 are each sized to be transported within a predetermined
width limit for transportation. For example, the maximum dimensions
for transportation by road may be 50 feet long, 20 feet wide and 12
feet high. If the modular building units 8, 10, 12, 80 and 11 are
each this size, they can be transported by road when unassembled
but the resulting building, when assembled, is too large and
exceeds the predetermined width limit when assembled.
[0093] What has been described is merely illustrative of the
application of the principles of the invention. Other arrangements
and methods can be implemented by those skilled in the art without
departing from the spirit and scope of the present invention.
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