System For Modular Construction

Abstract

A building structure composed essentially of components for a system of modular construction, including bottom angle members defining an L-shaped recess about the periphery of a slab foundation, structural post members positioned within the recess and spaced from the bottom angle members, truss members held by pairs of post members so as to span the distance across the foundation, and top angle members likewise spaced from the post members and positioned so as to avoid interference with the truss members. The building structure is completed by positioning prefabricated panel members between the post members and the top and bottom angle members, and placing prefabricated roof panels upon the truss members. The upright post members can be structural steel I-beams provided with flange extensions forming slots to receive the truss members. The wall panels can abut behind the post members, and can have cooperating recesses to receive the truss members. The described system of modular construction facilitates rapid assembly of a building structure with unskilled labor, and without use of nails or like penetrating means.

Description

SUMMARY OF THE INVENTION AND OBJECTS

This invention relates generally to systems for modular construction, and more particularly to such systems making use of preformed and prefabricated components that can be readily mounted on a slab foundation so as to facilitate rapid assembly at the construction site.

In general, it is an object of the invention to improve upon systems for modular construction of the type described, particularly with respect to means by which upright post members can be rapidly assembled upon a foundation in conjunction with roof truss members, in such fashion as to facilitate placement and attachment of preformed roof and wall panels without use of nails or like attachment means.

It is another object of the invention to provide a system for modular construction of the type described employing readily available structural components such as steel I-beams and angle members, in conjunction with preformed panel and truss members, whereby a substantially completed building structure can be assembled in a minimum of time.

A further object of the invention is to provide a system for modular construction wherein the components are easily and inexpensively manufactured, easily transported to the construction site, and easily employed in the erection of buildings of predetermined architectural design.

A still further object of the invention is to provide a system for modular construction employing available and preformed components, which requires only a minimum of on-site labor for erection and finishing procedures to prepare the building for occupancy.

A still further object of the invention is to provide a system for modular construction of the type described which facilitates rapid assembly of a building structure with unskilled labor, and without the use of nails or like penetrating means.

A still further object of the invention is to provide a system for modular construction of the type described which enables a building structure to be readily assembled and used, and just as easily disassembled for transport and use at another building site.

Additional objects and features of the invention will appear from the following detailed description of the same, and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a building structure employing components for a system of modular construction embodying the invention.

FIG. 2 is a like view showing a partially completed stage of construction, prior to attachment of any roof or wall panels.

FIG. 3 is a fragmentary isometric view showing a group of prefabricated wall panels as aligned for assembly on the framework of FIG. 2.

FIG. 4 is an enlarged view in vertical section along the line 4--4 of FIG. 1.

FIG. 5 is an enlarged detail view, in section and elevation, of the portion 5--5 of FIG. 4.

FIG. 6 is a like view along the line 6--6 of FIG. 5.

FIG. 7 is a detailed view in perspective, with parts in phantom, particularly illustrating the means for attachment of truss and panel members at the top of an upright post member.

FIG. 8 is a like view, particularly illustrating the means for attachment of post and panel members at the bottom of an upright post member.

FIg. 9 is a detailed view, like FIG. 8, illustrating assembly of post and angle members at a corner of a building structure according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention generally provides a system for modular construction wherein use is made of available or readily fabricated modular components, and which facilitates the rapid construction of residences, offices, and like structures intended for human habitation.

In a completed building structure, the modular components include a series of bottom structural angle members which define the peripheral boundaries of a slab foundation, and a series of upright structural I-beams or like post members which are mounted at a predetermined spaced distance from the angle members. The post members are arranged in parallel fashion on opposite sides of the slab foundation, and have upstanding recessed attachment means to receive and support horizontal truss members. Top structural angle members are mounted adjacent the top of the post members, likewise at a predetermined spaced distance from the post members, and in parallel, vertically spaced relation with respect to the bottom angle members. The top angle members are also positioned so as to avoid interference with the recessed attachment means for the truss members. The latter span the distance between the two lines of parallel post members and provide a means for attachment and support of roof panels. The building structure is completed by a series of prefabricated wall panels which are of a thickness to be received between the upright post members and the top and botom angle members, and which are dimensioned to span the longitudinal distance between the post members. Preferably the wall panels are prefabricated to provide both interior and exterior wall surfaces for the structure, and to abut behind the post members so as to avoid exposure of seams on the exterior of the building structure. Top portions of adjacent wall panels can also be provided with cooperating corner recesses to facilitate passage of a truss member.

In general, the structural steel angle members and I-beams used as posts, can be obtained from commercial sources of supply for such construction materials. The wall panels can also be obtained from commercial sources, with but little variation in the manufacturing procedure or instructions to the manufacturer. The disclosed system for modular construction thus makes possible the rapid and efficient erection of building structures according to virtually any architectural plan, with use of available unskilled labor, and in periods of time which are a fraction of the times normally required for similar construction.

Referring to the drawings in detail, 10 indicates a building structure wherein modular components according to the invention (visible from the exterior of the building) include a foundation as generally represented at 12, a series of upright post members 14 arranged in parallel fashion along two sides of the foundation, wall panels 16 of various types and configurations, and roof panels 18. As particularly illustrated in FIGS. 2, 4 and 8, the foundation 12 is in the form of a concrete "slab," wherein the peripheral boundary is defined by a series of structural L-shaped angle members 20. It is a particular advantage of the described system, that the angle members 20 can be rapidly and accurately positioned adjacent the upright post members 14, thereby insuring proper placement of the wall panels 16 at the time of erecting the building structure 10. In this regard, the angle members 20 cooperate in the formation of a generally L-shaped, outwardly facing recess 21 in the upper peripheral boundary of the slab foundation, wherein the upstanding post members 14 are positioned at a predetermined spaced distance from upright portions 22 of the angle members. Thus, as particularly illustrated in FIG. 8, the L-shaped angle member 20 has an upright portion 22 which is spaced at a distance 24 from the post member 14, which distance approximates the thickness of the wall panels 16.

With further reference to FIG. 8, it will be seen that each of the post members 14 can be provided with a base mounting which preferably is in the form of a plate 26, welded or otherwise integrally secured to the bottom of the post member. The base mounting plate 26 facilitates the mounting of the post members within the recess 21 of the foundation, and the ready attachment of the post members to the foundation by means of lag bolts 28 or other suitable attachment means. For example, in a typical construction procedure, the foundation 12 might be poured with recess-forming boards held in place about the periphery by means of foundation inserts of desired size (e.g., inverted lag bolts), positioned at the point of placement of the posts. Upon removing the edge boards, the post members 14 can be readily mounted within the resulting recess 21 by means of the plate members 26. Thus, as generally illustrated in FIGS. 2 and 8, the plate members 26 are provided with apertures to receive the foundation inserts 27, and are secured in place by means of the outer locking nuts 28.

Following placement of the post members 12, the bottom angle members 20 can likewise be secured to the foundation inserts 27, and also to the base plate 26, by means of inner locking nuts 30. Thus as particularly illustrated in FIG. 8, the foundation inserts extend upward through the base plate and also through apertures provided in the lower flange 25 of the angle member 20, thereby insuring that the post members 14 are positioned in desired spaced relation from the upright flange portion 22 of the foundation recess 21. Additional foundation attachments such as expansion type lag bolts 31 and spacing washers 32 can be provided to hold the angle members 20 firmly in place between the post members 14, at the peripheral boundary of the concrete slab 12 (see FIGS. 8 and 9). In this fashion, a series of angle members 20 can be readily positioned in desired space relation with respect to a series of upright posts members 14, on two opposite parallel sides of the foundation 12 (see FIG. 2).

Referring particularly to FIGS. 2 and 9, angle members 20 can be assembled in similar fashion on the ends of the slab foundation. In this case, however, the intervening post members 14 can be omitted so that only the outer ends of the angle members will be supported on the base plates of the corner post members. Intervening portions of the angle members 20 can be held in place by lag bolts 31, and spacers 32, as previously described.

As illustrated, the upright post members 14 are preferably in the form of structural steel I-beams having web portions 34 and parallel flange portions 36. As best illustrated in FIG. 2, these members are arranged so that the web portions are parallel to the line of the wall whereas the flange portions are perpendicular to the line of the wall. This arrangement provides a maximum resistance to bending moments in the plane of the walls, as represented by the panels 16. The described arrangement also facilitates the provision of upstanding attachment means 38 in the form of extensions of the flanges 36 of the I-beams. Thus, as particularly shown in FIGS. 2 and 7, the post members 14 have cross plates 40, above which the web portions 34 are omitted to thereby provide recessed passages 42 extending transversely to the line of the wall. This arrangement facilitates the rapid asssembly of cross bracing joist assemblies or truss members 14, which function to span the horizontal distance between a pair of post members 14 on opposite sides of the foundation (see FIG. 2).

Referring particularly to FIGS. 4 through 7, the truss members 44 can be in the form of prefabricated rafter assemblies, including lower cross members 46 and upper roof forming members 48 interconnected by cross bracing 50. The truss members are secured within the upstanding attachment means of the post members by means of upper and lower cross bolts 52, which pass through the members 46 and 48 and which are tied to one another by means of the apertured rods 54. In general, the particular design of the truss members 44 is not critical to the invention, and these members can be obtained from a suitable commercial source. In this regard, the pitch dimensions and degree of overhang of the roof forming members 48 will generally be determined by the requirements of a particular construction project.

Following erection of two generally parallel series of upright posts 14 on opposite sides of the foundation 12, the truss members 44 are lowered into position within the recesses 42 of the upstanding attachment means 38, and firmly locked in position by the bolts 52. The general procedure is illustrated in FIG. 2, which shows a stage in the assembly of the truss members 44 on the post members 14. Thereafter, the top angle members 60 are mounted at an inwardly spaced position between the adjacent post members 14, and at a desired vertical distance above the bottom angle members 20. In the illustrated embodiment, this is accomplished by attaching the top angle members 60 (which may be in the form of structural steel T-bars) to the extending flange portions 36 of the upstanding attachment means 38. Thus, as particularly illustrated in FIGS. 5 and 6, the angle members 60 are demountably assembled on the members 36 by means of inwardly extending plates 62 and suitable attachment means 64. As in the case of the bottom angle members 20, inner vertical surfaces of the angle members 60 are spaced from the post members 14 at a distance which approximates the thickness of the wall panels 16. The mounting of the top angle members 60 by means of the attachment plates 62 also facilitates positioning of the top angle members at any desired vertical distances from the bottom angles 20, as required by the vertical height of the wall panels 16. The mode of attachment also avoids intrusion of the attachment means into the transverse slots 42 for the truss members 44.

As will be apparent from the foregoing, the mounting of the top and bottom structural angle members 60 and 20 at a spaced horizontal distance from the post members, and at a predetermined vertical distance from each other, facilitates the ready assembly of wall panels 16 between the peripheral edges of the foundation and the posts. Thus, as will be apparent from FIGS. 2 and 4, the wall panels 16 can be received within the slots provided at the bottom by the post members 14 and the legs 22 and 25 of the L-shaped brackets 20, and at the top by the post members and the upright 66 and horizontal leg 68 of the angle members 60. If desired, the prefabricated wall panels 16 can be positioned behind the post members 14 so that their adjacent vertical edges abut or form a seam which is hidden by the web 34 of the post members (see FIG. 3). Also, to facilitate passage of the truss members 44, the wall panels can be conveniently provided with recessed corners 70, dimensioned so that the paired recesses correspond in width to the recessed openings 42 of the post members. As particularly shown in FIg. 7, this arrangement facilitates passage of a truss member without loss of structural support, and without interfering in any way with the placement of the panels between the top and bottom angle members 60 and 20.

At the ends of the building structure, the wall panels 16 can be assembled directly against the lower angle members 20 and the cross member 46 of the end truss member 44. For such purpose, the upright portions 22 of the bottom angles 20 can be provided with apertures to facilitate attachment by means of wood screws or the like. Such procedure can also be employed along the lower periphery of the side wall panels, as schematically represented at 72 in FIG. 4.

In general, the wall panels 16 can be prefabricated to meet desired design requirements. For example, a typical wall panel 16 can have an exterior skin of wood or like material, as conventionally produced in the factory by a plywood fabricator. In like fashion, the interior skin of a panel can be formed of plastic composition, textured plywood, and so on. The wall panels can also be constructed to include suitable insulation materials, foil lining, and the like, as may be required by local building codes and fire regulations. Many variations in the precise construction of the wall panel units 16 are therefore contemplated. For purposes of the invention, the only requirement is that the dimensions be generally conformable to a desired vertical spacing between the top and bottom angle members 60 and 20, and the horizontal spacing between the upright post members 14. Thus, as noted previously, the vertical positioning of the attachment plates 62 is easily adjusted in a given construction project to accommodate wall panels of varying height. The only adjustment would be a variance in the dimension of exterior blocking utilized to fill the vertical space between the tops of the panels and the truss members 44. In like fashion, the post members 14 will generally be spaced according to a standard module, determined by the dimensions of the prefabricated panel components. It will be appreciated, therefore, that the modular system of the present invention is quite flexible and highly adaptable to a variety of constructional requirements.

Following assembly of the truss members 44 on the upright post members 14, and either before of after assembly of the wall panels 16 in the manner described, the roof panels 18 can be mounted directly on the upper truss members 48. This arrangement is schematically illustrated in FIG. 1. The roof panels can be of desired prefabricated construction as manufactured and sold by a number of commercial sources. As further represented schematically in FIG. 4, the roof panels 18 provide convenient support for conventional roofing materials such as tar and gravel, asphalt shingles and the like, as generally represented at 76. Finish details with respect to the roof panels 18 and applied roofing materials can therefore be according to conventional practice, for example, including the placement of gutters 78, fascia boards 80, and the like.

The utility of the system for modular construction as herein described, and as employed in a typical construction project, will now be briefly summarized. Assuming a rectangular one level building structure, as represented in FIGS. 1 and 2, a slab foundation can be poured with edge boards held in place by appropriately spaced lag bolts 27. Upon removing the edge boards, the upright post members 14 can be mounted on two sides of the slab foundation and within the peripheral recesses 21 formed by the edge boards, utilizing the mounting plates 26. The bottom angle members 20 can now be assembled within the recesses 21, in desired spaced relation upon and between the mounting plates 26. Thus, as particularly illustrated in FIGS. 2, 4 and 8, the positioning of the bottom angle members 20 upon the inner lag bolts 27, insures the predetermined spacing 24 between the inner edges of the upright posts 14 and the upright portions 22 of the bottom angle members 20. Next, the truss members 44 are placed within the recessed openings of the attachment means 38 of opposing pairs of post members 14, and bolted into place by means of the bolts 52. The top angle members 60 can now be positioned by means of the brackets 62, the wall panels 16 mounted within the slots or spaces formed between the upright post members 14 and the top and bottom angle members 60, 20. In this activity, it may be more convenient to first place the panels 16 within the bottom slots prior to attaching the top angle members by means of the brackets 62. In either event, the panels are chosen according to the architect's plan, to provide window and door spaces in the desired locations. In the course of such assembly, the panels are received behind the posts in such fashion that the seams of the abutting vertical edges are hidden behind the webs 34 of the post members 14, and so that the recesses 70 cooperate to receive the outwardly extending portions of the truss members 44. The structure is completed by mounting the roof panels 18 on the upper surfaces 48 of the truss members, following which the structure can be made essentially water and airtight by application of blocking, calking, roofing materials, etc., in conventional fashion.

From the foregoing, it will be apparent that the described system for modular construction provides many advantages, foremost of which is the ability to rapidly assemble a building structure with unskilled labor and in a minimum of time, and without the use of nails or like attachment means. The means for demountably assembling the various components also makes possible the disassembly of the building structure for re-use at a different location, again with a minimum of effort and requirement of construction skills. In a typical construction project, a standard residential unit might be erected by a three or four man construction team, in a period of 2 weeks or less, at a cost approximating 20 percent or less of the cost of the preformed or prefabricated components.

To those skilled in the art to which this invention relates, many different applications and embodiments will suggest themselves without departing from the spirit and scope of the invention. For example, while the upright post members 14 have been shown as structural steel members with integral base plates for attachment to the foundation, it will be apparent that a separate base plate with a vertical extension adapted to be bolted or otherwise demountably attached to the web or flange portions of the post members, would be equally satisfactory. Likewise, structural aluminum or like materials of equivalent strength might be utilized in place of the structural steel components. Accordingly, it should be understood that the disclosures herein are intended to be purely illustrative and not limiting except as defined in the claims.

Claims

I claim:

1. In a system for modular construction, a series of elongate outwardly facing bottom angle members forming an integral part of the foundation of a building structure, said angle members having upright portions coincident with a periphery of said foundation, upright post members attached to said bottom angle members along at least two opposite sides of said building structure, said post members being spaced outwardly and at a predetermined horizontal distance from the upright portions of said angle members, said post members having upstanding attachment means at their tops, a series of prefabricated truss members supported by pairs of said post members positioned on said opposite sides of the building structure and held in place by said attachment means, each of said truss members spanning the horizontal distance between a supporting pair of said post members, elongate outwardly facing top angle members interconnecting said post members at a spaced vertical distance above the bottom angle members on said two sides of the building structure, said top angle members having upright portions spaced inwardly at substantially said predetermined horizontal distance from said upright post members, a plurality of prefabricated wall panels positioned with respect to said upright post members so that top portions of said panels are held between said top angle members and said post members and bottom portions of said wall panels are held between said bottom angle members and said post members, and a plurality of prefabricated roof panels attached to and supported by said truss members, said upright post members, truss members, wall panels, and roof panels combining to form an essentially complete building structure.

2. A system for modular construction as in claim 1 wherein said foundation is a slab foundation and said bottom angle members include upright portions defining an exterior boundary of said slab foundation.

3. A system for modular construction as in claim 2 wherein said bottom angle members are structural steel members of substantially L-shaped cross section.

4. A system for modular construction as in claim 1 wherein said upright post members are structural steel I-beams arranged so that the flange portions are perpendicular to the plane of a wall formed by said wall panels.

5. A system for modular construction as in claim 4 wherein each said post member is mounted on a base plate which is rigidly secured to one of said bottom angle members.

6. A system for modular construction as in claim 1 wherein each of said truss members includes a substantially horizontal strength member and at least one inclined strength member secured thereto by truss bracing members, said inclined member establishing the roof plane of said building structure.

7. A system for modular construction as in claim 6 wherein top angle members are of T-shaped configuration.

8. A system for modular construction as in claim 1 wherein each of said top angle members including said upright portion is a structural steel member, said upright portion being arranged so that it is parallel to and coincident with the top of a wall panels and is horizontally spaced inwardly from an upright post member a distance approximating the thickness of said wall panel.

9. A system for modular construction as in claim 1 wherein adjacent upper corners of said wall panels are cut away to provide recess means dimensioned to facilitate reception of a truss member within the attachment means of an upright post member in front of the abutting vertical edges thereof.

10. A system for modular construction as in claim 1 wherein adjacent vertical edges of said wall panels abut at positions behind said upright post members.

11. A building structure composed essentially of components useful in a system of modular construction, comprising: a generally rectangular slab foundation, a series of structural bottom angle members having an upright portion, said bottom angle member defining the peripheral boundary of said slab foundation and forming a continuous outwardly opening L-shaped recess in the edge thereof, a series of upright structural post members attached to said bottom angle member at spaced position along at least two opposite and parallel sides of said slab foundation, said post members being supported adjacent the L-shaped recess formed by said bottom angle members and at a predetermined horizontal distance outwardly from the upright portions thereof, said predetermined horizontal distance approximating the thickness of wall panels received between said bottom angle members and said upright post members, each of said post members being provided with upstanding spaced apart attachment means defining transverse slots at the tops thereof, a series of structural top angle members defining upper peripheral boundaries for said wall panels, end portions of said top angle members being supported at their ends on the upstanding attachment means of said post members so as to avoid interference with the transverse slots in said attachment means, said top angle members likewise being spaced at said predetermined horizontal distance inwardly from said post members to thereby accommodate the thickness of said wall panel members, said top angle members also being in horizontal alignment with said bottom angle members, a series of prefabricated truss members defining the roof planes of said building structure, each of said truss members extending horizontally through the transverse slots of at least two post members so as to span the horizontal distance between said post members, said truss members being thereby supported at a predetermined vertical distance above said slab foundation, a plurality of prefabricated wall panels of vertical dimension to be received between said top and bottom angle members and of horizontal dimension sufficient to span the distance between adjacent upright post members on a common edge of said slab foundation, said prefabricated wall panels being provided with corner recesses in upper portions thereof to accommodate said truss members, and prefabricated roof panel members attached to and supported by said truss members, said slab foundation upright post members, top and bottom angle members, wall panels, and roof panels defining a substantially complete building structure.

12. A building structure as in claim 11 wherein said upright post members are steel I-beams having web portions parallel to the plane of said wall panels and flange portions perpendicular to the plane of said wall panels.

13. A building structure as in claim 12 wherein said I-beams are provided with integral bottom plate members, said bottom plate members being provided with apertures to facilitate attachment to said bottom angle members.

14. A building structure as in claim 12 wherein the upstanding attachment means of said post members are formed as extensions of the flange portion of said I-beams.

15. A building structure as in claim 11 wherein said bottom angle members are provided with vertical portions protruding above the plane of said slab foundation, said vertical portions being provided with apertures cooperating with attachment means in engagement with lower portions of said prefabricated wall panels.