Patent Grant
8156691
The present disclosure generally relates to modular building structures. More specifically, the present disclosure relates to modular building structures designed to be constructed off-site and transported using standard load transport.
Correctional facilities typically include a plurality of cells for inmates that are incarcerated on the premises. The cells constitute living quarters for the inmates during their incarceration. In many cases, cells are arranged in two levels where the top level of cells is placed directly over the lower level. The top level of cells commonly has a landing of approximately 4 feet in width and extending the length of the cells to enable inmates incarcerated on the upper level to enter and exit their cells.
Cells are constructed out of poured concrete. The concrete can be poured and allowed to form a single structure in order to enhance the strength of the structure. Cells are commonly grouped together in groups of, for example, two cells (“double module”) or four cells (“quad module”). When fabricating double module cells, the landing and the cells are typically cast monolithically. However, the quad module cells and the landing are commonly fabricated separately and attached together at the correctional facility. However, using multiple concrete elements increases cost.
In some cases, the cells are produced off-site and are transported to the correction facility for installation. As commonly constructed, the cells are approximately 14 feet in width from front to back. Because the landing extends approximately an additional 4 feet from the front of the cell, the entire width of the cell block is approximately 18 feet.
Trucking companies must abide by various wide load and/or super load restrictions determined by each state. For example, when transporting a load over 16 feet in width in Pennsylvania, trucking companies are required to obtain a permit for a super load that requires a police escort. In most cases, a long lead time is required to obtain a super load permit. Moreover, most states only issue a limited number of super load permits per day for a single point of origin. Thus, super load transport is generally considered to be undesirable for at least the reasons listed above.
In contrast, a load between approximately 8.5 feet and 16 feet is merely classified as a wide load. In particular, a load between 13 feet and 16 feet is classified as a wide load that requires a car escort and for which permits are routinely issued. As such, the cost of transporting wide loads is significantly less than the cost of transporting super loads and the time to obtain permits for such loads is substantially less than for super loads.
This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope.
As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. All publications mentioned in this document are incorporated by reference. All sizes recited in this document are by way of example only, and the invention is not limited to structures having the specific sizes or dimensions recited below. Nothing in this document is to be construed as an admission that the embodiments described in this document are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term “comprising” means “including, but not limited to.”
In an embodiment, a modular building structure may include a plurality of walls including a front wall, a ceiling positioned at a top portion of each of the walls, the ceiling having a top surface, and a landing connected to the ceiling by one or more pin assemblies. The one or more pin assemblies may be configured to enable the landing to be moved between a retracted position and an extended position. An upper surface of the landing may be adjacent to a top surface of the ceiling when the landing is in the retracted position, and the landing may extend from the front wall when the landing is in the extended position.
In an embodiment, a method of forming a modular building structure may include inserting a plurality of pin assemblies into a mold that defines inner and outer surfaces for each of a plurality of walls, a ceiling and a landing for a modular building structure. Each of the plurality of pin assemblies may be inserted at a location between a portion of the mold defining the ceiling and a portion of the mold defining the landing. The method may further include inserting a separator at a location proximate to each of the plurality of pin assemblies, pouring liquid concrete around the mold, allowing the liquid concrete to set, separating the modular building structure from the mold, and removing the separator from the modular building structure. The plurality of pin assemblies may be configured to enable the landing to be moved between a retracted position and an extended position.
In an embodiment, a modular building structure may include a plurality of walls including a front wall, a ceiling having a top surface positioned at a top portion of each of the walls, and a landing connected to the ceiling by one or more pin assemblies. The plurality of walls and the ceiling may form a contiguous structure having no seams. The one or more pin assemblies may be configured to enable the landing to be moved between a retracted position and an extended position. An upper surface of the landing may be adjacent to a top surface of the ceiling when the landing is in the retracted position, and the landing may extend from the front wall when the landing is in the extended position. Each pin assembly may include a pin, a cell-side portion connected to the ceiling, and a landing-side portion connected to the landing. The cell-side portion may include a receiving structure and a first supporting structure connected to a bottom side of the receiving structure. The landing-side portion may include a pin-receiving structure proximate to the receiving structure of the cell-side portion, a second supporting structure and a first headed concrete anchor.
In an embodiment, the receiving structure 105 may have outer dimensions of approximately 5″×6″×7″ and be approximately ½″ thick. In an embodiment, the hole 110 in the receiving structure 105 may be approximately 1″ in diameter to accommodate the pin 115, which has substantially the same diameter. In an embodiment, a hole 110 may be present on each of two opposing sides of the receiving structure 105 such that the pin 115, when inserted, may extend through and out both sides of the receiving structure. In an embodiment, the first supporting structure 120 may be approximately 3.5″×6″×7″ and may be approximately ⅜″ thick. In an embodiment, the third supporting structure 125 may be approximately 3″×3″×9″ and may be approximately ⅜″ thick. As shown in
In an embodiment, the pin-receiving structure 205 may have outer dimensions of approximately 2″×4″×6″ and be approximately ½″ thick. In an embodiment, the hole 210 in the pin-receiving structure 205 may be approximately 1″ in diameter to accommodate the pin 115. The hole 210 may be configured to align with the hole 110 of the cell-side portion of the pin assembly 100. In an embodiment, a hole 210 may be present on each of two opposing sides of the pin-receiving structure 205 such that the pin 115, when inserted, may extend through and out both sides of the pin-receiving structure. In an embodiment, the second supporting structure 215 may be approximately 2″×10″×6″. As shown in
In an embodiment, the outer dimensions of the main portion of the modular building structure 300 may be approximately 103.5″ high and approximately 168″ long. In an embodiment, the top side 315 of the main portion of the modular building structure 300 may be approximately 5″ thick, and each wall, such as 320, of the main portion of the modular building structure may be approximately 6″ thick. In an embodiment, the thickness of the top side 315 and walls 320 of the main portion of the modular building structure may correspond to the dimensions of the cell-side portion of the pin assembly 100.
The modular building structure 300 may additionally include a landing 310 that is approximately 48″ in length. As further shown in
A lifting loop 520 may be attached to the landing 505 when the landing is setting. The lifting loop 520 may be used to assist in moving the landing 505 from a retracted position to an extended position (as is shown in
The modular building structure 600 may be configured to be transported as a unit by placing the landing 610 in the retracted position. In such a position, the modular building structure 600 may be within size restrictions for wide load transport for a plurality of jurisdictions. The landing 610 of the modular building structure 600 may be moved to the extended position for use as a walkway when, for example, the modular building structure is installed at an installation site.
Each cell, such as 605a, may have a door opening, such as 620, for entering the cell and may further be proximate to an enclosed space, such as 625, for providing utilities and plumbing to the cell. Connections between the utilities and plumbed devices in a cell 605a and the utilities and plumbing in an adjacent enclosed space 625 may be made, for example, at the installation site.
In an embodiment, a plurality of modular building structures 600 may be placed side-by-side to form a block of cells. In an embodiment, a plurality of modular building structures 600 may be stacked one atop another to provide multiple levels of cells. In such an embodiment, the floor of the cells in an upper modular building structure may be the ceiling of a lower modular building structure. In an embodiment, an upper modular building structure may not include a landing.
A separator may be inserted 710 at a location proximate to the plurality of pin assemblies. The separator may be used to prevent concrete from solidifying between the front wall of a modular building structure and the landing. The separator may extend from one side of the mold to the other, and may be interrupted at each pin assembly. In an embodiment, the separator may be made of fiberglass or any other material that can be removed from the concrete after it sets.
Liquid concrete may be poured 715 into and/or around the mold. The liquid concrete may be prevented from entering the pin assemblies because the pin assemblies may be encased in a protective structure.
The liquid concrete may then be permitted to set 720. Once the concrete has set, the modular building structure may be removed 725 from the mold. In an embodiment, the mold may include hydraulic or mechanical mechanisms to assist in removing the modular building structure from the mold. When the concrete has set 720, the modular building structure may be removed 725 by, for example, compressing one or more portions of the mold using the hydraulic or mechanical mechanisms. Because the modular building structure is now formed of solid concrete, collapsing the walls and removing 725 the one or more cores may not cause the concrete to lose its shape.
The separator may also be removed 730 from the modular building structure. In an embodiment, the separator may be removed 730 during or after causing the landing to be moved from an extended position to a retracted position.
As taught above in reference to
Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.
This application claims the priority benefit of U.S. Provisional Application No. 61/230,882 filed Aug. 3, 2009, the disclosure of which is totally incorporated herein by reference.
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| Number | Date | Country | |
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| Number | Date | Country | |
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| 61230882 | Aug 2009 | US |
