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WO2009061702A1 - Unité, système, et procédé de construction d'immeuble modulaire - Google Patents

Unité, système, et procédé de construction d'immeuble modulaire Download PDF

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Publication number
WO2009061702A1
WO2009061702A1 PCT/US2008/082277 US2008082277W WO2009061702A1 WO 2009061702 A1 WO2009061702 A1 WO 2009061702A1 US 2008082277 W US2008082277 W US 2008082277W WO 2009061702 A1 WO2009061702 A1 WO 2009061702A1
Authority
WO
WIPO (PCT)
Prior art keywords
building construction
modular building
concrete
modules
modular
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2008/082277
Other languages
English (en)
Inventor
Philip George Ellis
Morgan Jay Ellis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FRAMEMAX Inc
Original Assignee
FRAMEMAX Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by FRAMEMAX Inc filed Critical FRAMEMAX Inc
Publication of WO2009061702A1 publication Critical patent/WO2009061702A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
    • E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8605—Walls made by casting, pouring, or tamping in situ made in permanent forms without spacers

Definitions

  • the field of the invention relates to modular buildings and construction methods.
  • Modular buildings and construction methods in the past have been used mainly to construct single family housing.
  • Two separate, pre-manufactured modules or halves pre-manufactured at a manufacturing facility off site
  • These housing modules typically have a wood-framed structure, and occasionally have a steel- framed structure.
  • the normal method(s) for attaching the two, separate pre- manufactured modules or halves together is by nailing, bolting, and/or welding the frames the modules/halves together at the destination housing/job site.
  • each module may comprise one-half of the overall width of the completed structure.
  • the modules are typically designed for room-sized efficiencies, with the room walls normally forming the sides of each module.
  • an aspect of the invention involves a modular building construction unit, a modular building construction system, and a modular building construction method that allows for the quick, easy, and inexpensive construction of almost unlimited building heights, allows economical shipping of modules anywhere in the world, utilizes concrete (a construction material common throughout the world), and utilizes poured-in-place reinforced concrete construction (a common building construction process throughout the world).
  • the modular unit, system, and construction method includes using standard shipping-container-sized, pre-fabricated modules (e.g., room modules or corridor/hallway modules) as concrete supporting panels (e.g., forms or boxing) to allow the modular building system structure to be made of poured-in-place, reinforced concrete.
  • standard shipping-container-sized, pre-fabricated modules e.g., room modules or corridor/hallway modules
  • concrete supporting panels e.g., forms or boxing
  • the standard shipping-container-sized, pre-fabricated modules are standard in size and exactly or substantially the same outer dimensions as 20 foot, 30 foot, and 40 foot standard shipping containers. Thus, the height and width of all modules would be the same (e.g., 9 foot, 6 inches in height by 8 foot in width). However, similar to standard shipping containers, the modules would come in a variety of lengths (e.g., a 20 foot length module, a 30 foot length module, or a 40 foot length module). The modules are pre-manufactured at a central manufacturing facility (or facilities).
  • the modules are manufactured so that less fit-out components and installation are required on the destined job/housing site, reducing construction cost.
  • a room module includes pre-installed walls (painted, wallpapered), floors (with flooring), ceilings (with lights/fixtures), bathrooms, sinks, toilets, and showers, and is pre-wired/pre-plumbed.
  • a corridor/hallway module includes pre-installed walls (painted, wallpapered), floors (with flooring), and ceilings (with lights/fixtures).
  • the modules include hollow wall sections, ceiling sections, and/or floor sections to provide for services (e.g., electrical wiring and plumbing).
  • a foundation is constructed, and the modules are arranged on the foundation using a crane.
  • the modules are spaced a predetermined separation distance from each other, the separation distance varying with the pre-determined height of the modular building system (e.g., 5 floors, 10 floors, 30 floors).
  • a ten-story modular building system may require a separation distance of X
  • a twenty-story modular building system may require a separation distance of 2X
  • a thirty-story modular building system may require a separation distance of 3X.
  • the configuration in which the modules are arranged will determine the concrete forming structure for the concrete pouring process.
  • the external walls/rooftop of the modules form the concrete supporting panels of the concrete forming structure.
  • Reinforcements such as steel reinforcement rods are provided where needed (e.g., vertically oriented between modules and horizontally oriented above the top of modules) for providing the necessary reinforcement for the poured-in-place, reinforced concrete process.
  • Additional forms e.g., small metal plates attached to the modular units
  • Concrete is then poured into the forming structure created by the modules. Concrete is poured over the modules/forms, between the modules/forms, and around the reinforcement rods. The dried, formed concrete creates a monolithic T or H shaped concrete- reinforced support structure.
  • the modules in the present invention do not provide the structural support for the modular building system.
  • the modular construction method of the present invention eliminates most connection details of connecting modules, as was required in the past with prior modular construction, creates the walls of the concrete-reinforced support structure (including the shear walls), creates the floors of the concrete-reinforced support structure, and provides the structure to support the gravity loads of upper floors of the modular building system.
  • FIG. 15 Another aspect of the invention involves a modular building construction system including a) a plurality of modular building construction units of a predetermined length, width, and height that are substantially the same as standard shipping containers, the modular building construction units configured to be placed upon a foundation at specified separation distances, the modular building construction unit including outer surfaces, some of which act as forms for poured concrete; b) reinforcements configured to be placed between and above the modular building construction units; c) concrete poured over the reinforcements and formed by some of the outer surfaces of the modular building construction unit, whereby the concrete and reinforcements create a monolithic concrete-reinforced supporting structure for the modular building construction system; and d) one or more additional floors including a, b, and c whereby the concrete-reinforced supporting structure for the last completed floor forms the foundation for a, b, and c.
  • the modular building construction unit includes a length, a width, and a height that is substantially the same as the length, the width, and the height of a standard shipping container; and one or more external surfaces configured to serve as a form for poured-in-place concrete for creating a concrete-reinforced structure between and above adjacent modular building construction units.
  • a still further aspect of the invention involves a modular building construction method for constructing a modular building construction system.
  • the method includes a) constructing a foundation; b) arranging modular building construction units on the building foundation at predetermined separation distances dependent on a total height of the modular building construction system; c) providing reinforcements in areas between and above modular building construction units; d) using one or more external surfaces of modular building construction units as concrete forms and pouring concrete in areas between and above modular building construction units, around reinforcements to form a monolithic concrete-reinforced structure; e) repeating steps a-d for each additional floor whereby the concrete- reinforced structure for the last completed floor is the constructed foundation in step a.
  • FIG. 1 is a perspective view of an embodiment of a modular building construction unit
  • FIG. 2 is a perspective view of another embodiment of modular building construction unit and shows shipping container connectors used for lifting and moving the modular building construction unit;
  • FIG. 3 is a top view of an embodiment of a modular building construction system
  • FIG. 4 is a cross-sectional view of an embodiment of the modular building construction unit of FIG. 1 ;
  • FIG. 5 is a front elevational view of the modular building construction system of FIG. 3;
  • FIG. 6 is a flowchart of an embodiment of a modular building construction method.
  • modular building construction unit 100 a modular building construction system 110
  • modular building construction method 115 a modular building construction method 115
  • module The modular building construction unit
  • system the modular building construction system 110
  • method the modular building construction method 115
  • the pre-fabricated module 100 has a substantially rectangular block-shaped configuration.
  • the module 100 comes in pre-determined sizes, including a pre-determined length, width, and height.
  • the pre-determined size is substantially the same size(s) as standard shipping containers.
  • the height and the width of all modules are the same as the height and width of standard shipping containers, namely, 9 foot, 6 inches in height by 8 foot in width.
  • the modules 100 come in different lengths (e.g., a 20 foot length module, 30 foot length module, and a 40 foot length module).
  • the module 100 includes a top 120, a bottom 130, a left end 140, a right end 150, a front side 160, and a rear side 170.
  • the top 120, the bottom 130, the left end 140, the right end 150, the front side 160, and the rear side 170 are made of steel decking and connected to a module frame 180 made of 4 inch tubular steel.
  • the module 100 includes an inside surface 190 and an external surface 200.
  • FIG. 2 is a perspective view of another embodiment of a modular building construction unit 100.
  • the modular building construction unit 100 of FIG. 2 is similar to the modular building construction unit 100 of FIG. 1 , except the modular building construction unit 100 of FIG. 2 includes shipping container connectors 210 and 220.
  • the shipping container connectors 210 and 220 are used by cranes and other lifting equipment at shipping centers.
  • the shipping container connectors 210 and 220 are mounted on the external surface 200 and coupled to or integrated into the steel module frame 180.
  • the cranes and/or other lifting equipment use the shipping container connectors 210 and 220 at shipping centers to grab a hold of, handle, and move/stack the module 100, similar to that done with standard shipping containers.
  • the inside 190 of the module 100 varies in construction depending on the pre-determined use of the module.
  • FIG. 3 is a top view of an embodiment of the modular building construction system 110.
  • two basic types of modules 100 are used in the modular building construction system 110.
  • the two basic types of modules include room modules 100A-100D and a corridor/hallway module 100E.
  • additional/other types of modules are provided.
  • the modules 100 are manufactured at a central manufacturing facility (or facilities).
  • the modules 100 are manufactured so that little to no fit-out components and installation are required on the destined job/housing site, reducing overall construction cost.
  • a room module includes one or more of pre-installed finished walls (painted, wallpapered), floors (with flooring), finished ceilings (with lights/fixtures), bathrooms, sinks, toilets, and showers, and is pre-wired/pre-plumbed.
  • a corridor/hallway module includes pre-installed finished walls (painted, wallpapered), floors (with flooring), and ceilings (with lights/fixtures). Completing out as much as possible in the modules during manufacturing of the module reduces job site labor time/cost, accelerating site construction considerably, and eliminates the middleman margins in supplying all the fit-out components.
  • the modules 100A-100D include false wall sections 230A and 230B.
  • some modules 100 include one or more removable ends 140 and 150 and/or sides 160 and 170 (FIG. 1 ).
  • FIG. 1 For example, where two modules 10OA and 100B are placed side by side, opposing sides of the adjoining modules 100A and 100B are removable at the false wall sections 230A and 230B for connecting the two halves/modules 100A and 100B together to form a single room (16 ft. in width).
  • FIG. 4 is a cross-sectional view of modular building construction unit 100.
  • the module 100 of FIG. 4 illustrates hollow ceiling sections 240, hollow floor sections 250, and hollow wall sections 260.
  • the hollow ceiling sections 240, hollow floor sections 250, and hollow wall sections 260 allow for the provision of services such as electrical wiring and plumbing.
  • the floor is strong enough to support an 8 foot span across tube steel runners 270 (14g or 16g) at a 3 14 inch depth to sit above the concrete floor.
  • FIG. 5 is a front elevational view of the modular building construction system 110, and shows how concrete 280 is poured/applied using the modules 100 as forms for creating the reinforcing structure of the building.
  • the modules 100C, 100D are used as concrete supporting panels (e.g., forms or boxing) to allow the reinforcing structure to be made of concrete 280, which can be poured-in-place and reinforced.
  • the reinforcements 290 are metal rods such as rebar.
  • a foundation 300 is constructed.
  • the modules 100A and 100B are arranged on the foundation 300 using a crane (not shown).
  • the modules 100A and 100B are spaced a pre-determined separation distance 310 from each other.
  • the separation distance 310 varies with the pre-determined height of the modular building system 110.
  • the system 110 is two stories.
  • other building systems can be of substantially any height (e.g., 5 floors, 10 floors, 30 floors), so long as the separation distance 310 is appropriate.
  • a ten-story modular building system may require a separation distance 310 of X
  • a twenty-story modular building system may require a separation distance 310 of 2X
  • a thirty-story modular building system may require a separation distance 310 of 3X.
  • the configuration in which the modules 100A and 100B are arranged will determine the concrete forming structure for the concrete pouring process.
  • the external walls/rooftop of the modules 100A and 100B form the concrete supporting panels of the concrete forming structure.
  • the reinforcement 290 such as steel reinforcement rods, are provided where needed (e.g., vertically oriented between modules 100A and 100B and horizontally oriented above the top of modules 100A and 100B and beneath module 100C).
  • the reinforcement 290 provides the necessary reinforcement for the poured-in-place, reinforced concrete process.
  • Additional forms e.g., small metal plates attached to the modular units
  • the concrete 280 is poured into the forming structure created by the modules 100A and 100B. Concrete is poured over the modules 100A and 100B, between the modules 100A and 100B, and around the reinforcement 290. The dried, formed concrete forms a monolithic T or H shaped concrete-reinforced support structure.
  • the module 100C is placed on the concrete-reinforced support structure above the module 100A.
  • the present invention contemplates other arrangements for the second and/or subsequent floors.
  • the module 100C can be placed over the module 100B.
  • the module 100C can also be placed above the modules 100A and 100B substantially centered between the two.
  • an additional module can be placed next to the module 100C and above the module 100B to form a traditional four-walled base for a larger building that can be constructed by adding additional floors on top of each preceding floor.
  • FIG. 6 is a flowchart of one embodiment of a modular building construction method.
  • the method 115 begins at step 600 where a foundation is constructed, typically out of concrete.
  • the modules are arranged on the foundation at pre-determined separation distances, depending on the eventual height of the finished structure.
  • the separation between the modules creates a forming structure and at step 604, reinforcement in the form or rebar, for example, is provided or placed in the forming structure between and on top of the modules.
  • step 606 concrete is poured into the forming structure between the modules, on top of the modules, and around the reinforcement. Once the poured concrete dries, it creates a monolithic support structure.
  • step 608 if there are no additional floors, the method 115 is complete. Otherwise, the monolithic support structure is used at step 610 as a foundation for the next level. Thereafter, the method 115 repeats at step 602, wherein an additional floor is created on top of the preceding floor. The process continues until eventually there are no additional floors to add at step 608.
  • the modules in the present invention do not provide the structural support for the modular building system.
  • the modular construction method of the present invention eliminates most connection details of connecting modules, as was required in the past with prior modular construction, creates the walls of the concrete-reinforced support structure (including the shear walls), creates the floors of the concrete-reinforced support structure, and provides the structure to support the gravity loads of upper floors of the modular building system.
  • the concrete walls, floors, and ceilings of the system 110 provide better fire and acoustic qualities in the building and make the building more durable.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

L'invention concerne un système de construction d'immeuble modulaire comprenant a) une pluralité d'unités de construction d'immeuble modulaire ayant une longueur, une largeur et une hauteur prédéterminées qui sont sensiblement les mêmes que celles des conteneurs de transport standards, les unités de construction d'immeuble modulaire étant configurées pour être placées sur une fondation à des distances de séparation spécifiées, l'unité de construction d'immeuble modulaire comprenant des surfaces extérieures, dont certaines agissent comme des formes destinées à du béton déversé ; b) des renforcements configurés pour être placés entre et au-dessus des unités de construction d'immeuble modulaire ; c) du béton déversé sur les renforcements et formé par certaines des surfaces extérieures de l'unité de construction d'immeuble modulaire, de sorte que le béton et les renforcements créent une structure de support renforcée en béton monolithique pour le système de construction d'immeuble modulaire ; et d) un ou plusieurs planchers supplémentaires comprenant a, b, et c, de sorte que la structure de support renforcée en béton pour le dernier plancher réalisé forme la fondation pour a, b, et c.
PCT/US2008/082277 2007-11-06 2008-11-03 Unité, système, et procédé de construction d'immeuble modulaire Ceased WO2009061702A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US98588907P 2007-11-06 2007-11-06
US60/985,889 2007-11-06

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WO2009061702A1 true WO2009061702A1 (fr) 2009-05-14

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8365473B2 (en) 2008-03-14 2013-02-05 Build-Pod International Ltd. Prefabricated self-supporting construction element
US9234349B1 (en) 2013-08-30 2016-01-12 Convergent Market Research, Inc. Concrete panel system and method for forming reinforced concrete building components
DE102020002272A1 (de) 2020-04-14 2021-10-14 Wenker Gmbh & Co. Kg Hybridgebäude

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0932325A (ja) * 1995-07-20 1997-02-04 Kyokuto Kogyo Kk プレハブハウス
KR20010089315A (ko) * 1998-10-20 2001-09-29 윌리엄 리차드 찰스 스튜들리 용적형 모듈식 빌딩 시스템
KR20030008723A (ko) * 2001-07-19 2003-01-29 문석주 철골구조 건축물용 석재 외벽 판넬 및 그 제조방법
JP2004084310A (ja) * 2002-08-27 2004-03-18 Sekisui House Ltd 配線構造

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0932325A (ja) * 1995-07-20 1997-02-04 Kyokuto Kogyo Kk プレハブハウス
KR20010089315A (ko) * 1998-10-20 2001-09-29 윌리엄 리차드 찰스 스튜들리 용적형 모듈식 빌딩 시스템
KR20030008723A (ko) * 2001-07-19 2003-01-29 문석주 철골구조 건축물용 석재 외벽 판넬 및 그 제조방법
JP2004084310A (ja) * 2002-08-27 2004-03-18 Sekisui House Ltd 配線構造

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8365473B2 (en) 2008-03-14 2013-02-05 Build-Pod International Ltd. Prefabricated self-supporting construction element
US9234349B1 (en) 2013-08-30 2016-01-12 Convergent Market Research, Inc. Concrete panel system and method for forming reinforced concrete building components
DE102020002272A1 (de) 2020-04-14 2021-10-14 Wenker Gmbh & Co. Kg Hybridgebäude
EP3896235A1 (fr) 2020-04-14 2021-10-20 Wenker GmbH & Co. Kg Bâtiment hybride

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