System for modular building construction

• US 8,397,441 B2
• Filed: 06/29/2011
• Issued: 03/19/2013
• Est. Priority Date: 08/26/2006
• Status: Expired due to Fees

• Current Assignee: Global Building Modules, Inc.
• Original Assignee: Global Building Modules, Inc.
• Inventors: Wallance, David
• Primary Examiner(s): WENDELL, MARK R
• Application Number:
  US13/171,534
• Publication Number:
  US 20110252719A1
• Time in Patent Office: 629 Days
• Field of Search: 52/791
• US Class Current: 52/79.1
• CPC Class Codes: E04B 1/003 Balconies; Decks
• CPC Class Codes: E04B 1/34331 mainly constituted by three-dimensional elements
• CPC Class Codes: E04B 1/34336 Structures movable as a whole, e.g. mobile home structures vehicles comprising living accommodation for people, e.g. caravans, camping or like vehicles B60P3/32
• CPC Class Codes: E04B 1/34384 Assembling details for foldable, separable, collapsible or retractable structures
• CPC Class Codes: E04B 1/348 Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
• CPC Class Codes: E04B 1/34807 Elements integrated in a skeleton
• CPC Class Codes: E04B 1/3483 the supporting structure consisting of metal
• CPC Class Codes: E04B 2001/34892 Means allowing access to the units, e.g. stairs or cantilevered gangways
• CPC Class Codes: E04B 2103/06 of metal
• CPC Class Codes: E04H 1/005 Modulation co-ordination
• CPC Class Codes: E04H 1/04 Apartment houses arranged in two or more levels
• CPC Class Codes: E04H 2001/1283 Small buildings of the ISO containers type
• CPC Class Codes: F24D 3/145 Convecting elements concealed in wall or floor
• CPC Class Codes: Y02B 30/00 Energy efficient heating, ventilation or air conditioning [HVAC]
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Abstract

Construction systems for erecting building structures comprise a plurality of prefabricated interconnectable modular building units, each unit comprising a frame shaped as a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other units, the framing members comprising eight edge rails, at least one edge rail in one unit being interconnected by beam stitching with a respective edge rail in at least one other unit, the nodes and the exterior dimensions of the frame conforming to ISO shipping standards such that each unit is transportable using the ISO intermodal transportation system, and such that when the units are aggregated horizontally and vertically and adjacent units are interconnected, a building structure comprising at least one habitable space is formed. The modular units are assembled in a factory remote from the job site, and are there constructed to a semi-finished state, including installation of one or more of interior fit-out systems and finishes, exterior envelope systems, plumbing systems, electrical systems, environmental systems, and fire protection systems, following which the semi-finished modular units are transported from the factory to the job site, where they are craned into place and secured to form the structure being erected, a plurality of adjacent pairs of semi-finished modular units also being “stitched” together, and the semi-finished modular units are thereafter constructed to a finished state.

Claims

1. A system for building construction comprising a plurality of interconnectable pre-fabricated modular building units configurable in tandem to create a habitable building space, each unit comprising a frame shaped as a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other units, the nodes and the exterior dimensions of the frame meeting the ISO International Standards for intermodal transport, said framing members comprising a plurality of edge rails, at least one edge rail in one modular building unit being adapted for interconnection with a respective edge rail in at least one other modular building unit to form a flexurally stiffened composite beam, each said interconnectable edge rail having at least one non-nodal attachment point, each said at least one non-nodal attachment point comprising a bolt insertion aperture adapted to receive a bolt which is insertable therein, said flexural stiffening being achievable by positioning said interconnectable edge rails such that at least one bolt insertion aperture in one interconnectable edge rail is axially aligned with at least one bolt insertion aperture in the other interconnectable edge rail, and by securing said interconnectable edge rails to one another through said at least one non-nodal attachment point by inserting and tightening a bolt in said axially aligned bolt insertion apertures.

2. A system in accordance with claim 1 wherein said plurality of edge rails comprises eight edge rails.

3. A building structure comprising a plurality of interconnected pre-fabricated modular building units configurable in tandem to create a habitable building space, each unit comprising a frame shaped as a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other units, the nodes and the exterior dimensions of the frame meeting the ISO International Standards for intermodal transport, said framing members comprising a plurality of edge rails, at least one edge rail in one modular building unit being adapted for interconnection with a respective edge rail in at least one other modular building unit to form a flexurally stiffened composite beam, each said interconnectable edge rail having at least one non-nodal attachment point, each said at least one non-nodal attachment point comprising a bolt insertion aperture adapted to receive a bolt which is insertable therein, said flexural stiffening being achievable by positioning said interconnectable edge rails such that at least one bolt insertion aperture in one interconnectable is axially aligned with at least one bolt insertion aperture in the other interconnectable edge rail, and by securing said interconnectable edge rails to one another through said at least one non-nodal attachment point by inserting and tightening a bolt in said axially aligned bolt insertion apertures.

4. A building structure in accordance with claim 3 wherein said plurality of edge rails comprises eight edge rails.

5. A module for construction of a modular building structure, said module being prefabricated and comprising a frame shaped as a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other units, the nodes and the exterior dimensions of the frame meeting the ISO International Standards for intermodal transport, said framing members comprising a plurality of edge rails, at least one said edge rail being adapted for interconnection with a respective edge rail in at least one other module to form a flexurally stiffened composite beam, each said interconnectable edge rail having at least one non-nodal attachment point, each said at least one non-nodal attachment point comprising a bolt insertion aperture adapted to receive a bolt which is insertable therein, said flexural stiffening being achievable by positioning said interconnectable edge rails such that at least one bolt insertion aperture in one interconnectable edge rail is axially aligned with at least one bolt insertion aperture in the other interconnectable edge rail, and by securing said interconnectable edge rails to one another through said at least one non-nodal attachment point by inserting and tightening a bolt in said axially aligned bolt insertion apertures.

6. A module in accordance with claim 5 wherein said plurality of edge rails comprises eight edge rails.

7. A method for forming a habitable building space comprising the steps of (a) providing a plurality of construction modules, each said module being prefabricated and configurable in tandem with other modules to create a habitable building space, each said module comprising a frame shaped a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other modules, the nodes and the exterior dimensions of the frame meeting the ISO International Standards for intermodal transport, said framing members comprising a plurality of edge rails, at least one edge rail in one module being adapted for interconnection with a respective edge rail in at least one other module to form a flexurally stiffened composite beam, each said interconnectable edge rail having at least one non-nodal attachment point, each said at least one non-nodal attachment point comprising a bolt insertion aperture adapted to receive a bolt which is insertable therein, said flexural stiffening being achievable by positioning said interconnectable edge rails such that at least one bolt insertion aperture in one interconnectable edge rail is axially aligned with at least one bolt insertion aperture in the other interconnectable edge rail, and by securing said interconnectable edge rails to one another through said at least one non-nodal attachment point by inserting and tightening a bolt in said axially aligned bolt insertion apertures;

(b) fastening to the frame of each said module a floor system and a roof system comprising a ceiling, (c) assembling a plurality of said modules in at least two different dimensions, and (d) securing said modules together to provide a habitable building space.

8. A method in accordance with claim 7 wherein step (b) further comprises providing at least some of said modules with one or more systems selected from the group consisting of interior fit-out systems, exterior envelope systems, plumbing systems, electrical systems, environmental systems, and fire protection systems.

9. A method in accordance with claim 8 wherein said plurality of edge rails comprises eight edge rails.

10. A method of constructing a habitable building structure comprising the steps of (a) producing in a manufacturing facility a plurality of construction modules, each said module configurable in tandem with other modules to create a habitable building space, each said module comprising a frame shaped as a rectangular parallelopiped and comprised of framing members and a plurality of nodes, each node situated at a corner of said frame for selective interconnection with other modules, the nodes and the exterior dimensions of the frame meeting the ISO International Standards for intermodal transport, said framing members comprising a plurality of edge rails, at least one edge rail in one module being adapted for interconnection with a respective edge rail in at least one other module to form a flexurally stiffened composite beam, each said interconnectable edge rail having at least one non-nodal attachment point, each said at least one non-nodal attachment point comprising a bolt insertion aperture adapted to receive a bolt which is insertable therein, said flexural stiffening being achievable by positioning said interconnectable edge rails such that at least one bolt insertion aperture in one interconnectable edge rail is axially aligned with at least one bolt insertion aperture in the other interconnectable edge rail, and by securing said interconnectable edge rails to one another through said at least one non-nodal attachment point by inserting and tightening a bolt in said axially aligned bolt insertion apertures;

(b) constructing each of said plurality of modules to a semi-finished state in said manufacturing facility;

(c) transporting said semi-finished modules to a staging area at or near a construction site utilizing the ISO intermodal transportation system;

(d) preparing the construction site by providing a foundation for said building structure, wherein step (d) may be carried out prior to or simultaneously with step (c);

(e) craning a plurality of said semi-finished modules onto said foundation and securing said semi-finished modules to said foundation;

(f) fastening abutting semi-finished modules to one another at least through said nodes and through said at least one non-nodal attachment point; and

(g) constructing said semi-finished modules to a finished state, said construction comprising at least connecting utilities to said modules, to form one or more habitable spaces within said building structure, wherein step (g) may be carried out prior to or simultaneously with step (f).

11. A method in accordance with claim 10 wherein said plurality of edge rails comprises eight edge rails.

12. A method in accordance with claim 11 wherein the construction of each said module to a semi-finished state in step (b) comprises at least providing each said module with a floor and a ceiling.

13. A method in accordance with claim 12 wherein step (b) further comprises providing at least some of said modules with one or more systems selected from the group consisting of interior fit-out systems, exterior envelope systems, plumbing systems, electrical systems, environmental systems, and fire protection systems.

14. A method in accordance with claim 13 wherein at least some of said semi-finished modules may be configured with other adjoining semi-finished modules to produce at least one residential floor layout.

15. A method in accordance with claim 11 wherein step (e) comprises craning a first plurality of semi-finished modules onto said foundation, and wherein said method further comprises, subsequent to step (e), craning a second plurality of said semi-finished modules onto said first plurality of semi-finished modules to form a stack, and thereafter repetitively craning further pluralities of said semi-finished modules onto said stack to form a multi-story building structure.

16. A method in accordance with claim 15 wherein at least some of said semi-finished modules may be configured with other adjoining semi-finished modules to produce a plurality of residential floor layouts.

17. A method in accordance with claim 11 wherein, in step (a), each module is configured to provide at least a part of the floor layout of a finished habitable space, each module is adapted to be disposed with its sides and/or ends abutting another module, and the modules may be configured to produce at least one floor layout for habitable spaces within said modular building, wherein step (e) comprises craning one or more of said semi-finished modules onto said foundation and securing said one or more semi-finished modules to said foundation to form a ground floor, the method further comprising the steps of (h) craning another one or more semi-finished modules onto the previously-craned one or more semi-finished modules to form at least one stack;

and (i) repeating steps (f), (g) and (h) to form additional levels of said stack and to form one or more additional habitable spaces in each said additional level.

18. A method in accordance with claim 17 wherein step (b) further comprises providing at least some of said modules with one or more systems selected from the group consisting of interior fit-out systems, exterior envelope systems, plumbing systems, electrical systems, environmental systems, and fire protection systems.