Patent Application
20210332584
The embodiments relate to transportable building structures and, more specifically, relate to a containerized, transportable modular building system of pre-engineered, pre-assembled, adjustable structural components to form structural modules or elements to be used in building construction applications.
Concrete is a composite material composed of fine and coarse aggregate bonded together with a fluid cement that hardens over time. Many types of concrete exist, including cementitious and non-cementitious types, each having different means for binding aggregate together. Due to its vast building applications, concrete is one of the most frequently used building materials. In fact, its usage worldwide is, ton for ton, twice that of steel, wood, plastics, and aluminum combined.
Structural steel is a category of steel used for making construction materials in a variety of shapes. Many structural steel shapes take the form of an elongated beam having a profile of a specific cross section. Structural steel shapes, sizes, chemical composition, mechanical properties such as strengths, storage practices, etc., are regulated by standards in most industrialized countries. Most structural steel shapes, such as I-beams, have high second moments of area, which means they are very stiff in respect to their cross-sectional area and thus can support a high load without excessive sagging. While many sections are made by hot or cold rolling, others are made by welding together flat or bent plates.
Current construction methodologies usually use either structural steel or structural concrete. Many buildings utilize a reinforced concrete frame structure to meet building requirements, especially those of multi-level or high-rise buildings. Often, concrete is chosen as this material can be formed into almost any shape, it is more readily available and the constructability of this material is easier when compared to structural steel frame construction. When building with concrete, the sequence of construction requires that columns be poured first, followed by a supporting deck or table, shored to the floors below, which serves as a surface to hold wet concrete when pouring the floor above. The deck then becomes the working surface to pour the columns for the next level of construction. Often, each floor of a building requires four days to complete to ensure proper building techniques are employed. On Day 1, the columns are formed and vertical reinforcement is tied into place, and on Day 2 each column is poured and allowed to set. On Day 3, the table is jumped from the floor below and shored to support the wet load of concrete. Placement of reinforcement and other internal concrete slab elements commence on the deck. On Day 4, the deck is poured to complete the floor of the building. This process is then repeated for each floor until the building is complete. The aforementioned process is referred to as a “4 day cycle”. The time limiting factor of this building procedure is the time it takes for the concrete to cure and harden enough to become structurally viable enough to support the concrete's own dead load in order to become a self-supporting structure.
The aforementioned process forms a composite construction material comprising the concrete and reinforcement elements. The reinforcements correct the low tensile and ductile properties of concrete by including a reinforcement with a higher tensile strength and ductility.
When building with structural steel as a frame structure, the sequence of construction requires that pre-fabricated fixed length columns be set in place first, followed by supporting pre-fabricated fixed length horizontal beams. Longer sections are either welded or bolded together. The next level of columns and beams are subsequently installed. A corrugated metal deck is then installed at each level of the structure in line with the horizontal beams, which serves as a surface to hold wet concrete when pouring the floor. In this building procedure, the individual steel members are typically fabricated off site and then transported to the jobsite. On the jobsite, individual members are hoisted into position and either bolded or welded together using standard connection details familiar to those in the trade. The time limiting factor in this building procedure is the based on the fabrication process of the individual steel members, including the engineering, shop drawing and approval process and the logistics of shipping differently sized members to the jobsite. Once all of the components are on site, the vertical erection of the structural steel frame can be done much faster when compared to the vertical erection of a similar concrete framed structure. The erection time is only limited by the hoisting required to lift the individual members into place on the structure and the assembly labor required to assemble all of the columns, beams and other components. Construction with steel is more logistically challenging when compared to concrete due to the rigid nature of the material and all of assembly required of the individual components.
This summary is provided to introduce a variety of concepts in a simplified form that is further disclosed in the detailed description. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.
The present embodiments disclosed herein provide a structural building modular system, comprising a plurality of structural steel modules comprising a series of adjustable horizontal structural steel decks and adjustable vertical structural steel frames. The collapsed horizontal structural decks can be shipped stacked on top of each other or with a single deck positioned between a first side deck and a second side deck. The first and second side decks are each rotationally engaged to each side of the bottom deck to form, along with the vertical structural frames, a building module. In one version of the modular system, a track system within the horizontal structural deck, slidingly engages with a plurality of structural frames and includes a locking mechanism to retain the plurality of structural frames in position along a length of each of the bottom deck, the first side deck, and the second side deck. A plurality of corrugations are affixed to each of the bottom deck, the first side deck, and the second side deck to form a surface whereon concrete is poured.
The embodiments provide a system wherein the structural modules may be stacked upon one another to allow for multiple floors of a building to be constructed in a single day, rather than the four-day process common employed in the industry. The embodiments also allow for the elimination of the formwork and associated labor thereof commonly used in the arts. The system allows for the structural modules to be easily transported to the building site, anywhere in the world, using standard ISO shipping methodologies. Once at the construction site, the structural modules are readily constructed and stacked based on the building requirements. In such, the embodiments provide a means for modulating the dimensions of the structural module to accommodate varying building dimensions, including the ability to form patios, balconies, etc.
In one aspect, the plurality of corrugations are anchored to the bottom deck, the first side deck, and the second side deck via a plurality of nelson studs.
In one aspect, a perimeter forms an anchor for the plurality of nelson studs.
In one aspect, the perimeter comprises a protrusion to permit the concrete to be poured at a sufficient thickness above the corrugation.
In one aspect, the plurality of vertical structural frames are positioned on opposing sides of the bottom deck, the first side deck, and the second side deck to form a vertical shear wall.
In one aspect, each of the plurality of horizontal structural decks and vertical structural frames are extendable in the x-direction, the y-direction, and the z-direction.
In one aspect, the structural frames comprise a top beam, a bottom beam, a left beam, and a right beam, wherein each beam is extendable to increase the dimensions of the structural frame.
A more complete understanding of the present invention and the advantages and features thereof will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
The specific details of the single embodiment or variety of embodiments described herein are to a system and method of use. Any specific details of the embodiments are used for demonstrative purposes only and no unnecessary limitations or inferences are to be understood therefrom.
Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of components related to the system and method. Accordingly, the system components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
As used herein, relational terms, such as “first” and “second”, “top” and bottom”, and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements.
As used herein, when drawing in a 3-dimensional perspective view, the x and y axis are used to define a horizontal plane with 2 axes positioned at right angles or at 90 degrees to each other. The z-axis is used to define a 3rd vertical plane sitting at 90 degrees to both the x and y axis. This nomenclature for describing a 3-dimensional perspective view will be understood to those familiar in the art.
As used herein, in building construction engineering, when a wind load is applied to a building or structure, it creates a lever arm rotational moment around the axis or plane on which the load is applied. This terminology will be familiar to those in the art.
As used herein, in building construction engineering, the term “shear wall” is defined as a structural element or series of structural elements, that when aligned along an axis, resist the overturning moment created by a wind load. For building purposes, these axes are commonly aligned along the x and y axis and for engineering purposes, they work in tandem to resist forces and other rotational moments. This terminology for describing a shear wall will be well understood by those familiar in the art.
As used herein, the term “concrete” may include any concrete material including fine and coarse aggregates, fluid cements (of any type including lime-based cement binder, lime putty, hydraulic cements such as aluminate cement, or Portland cement). Concrete elements may also include non-cementitious types of concrete with various forms of binding aggregates. One skilled in the arts will readily understand that similar building materials with equivalent engineering or mechanical properties may be used along with the structural modular building system described herein.
As used herein, the term “structural steel” may include any steel elements including hot rolled or cold rolled steel in a variety of shapes and sizes, as well as corrugated sheets of structural steel and reinforcement steel with certain chemical compositions, engineering and mechanical properties, used for making construction materials in a variety of shapes and sizes. One skilled in the arts will readily understand that similar building materials or that similar building components with equivalent engineering or mechanical properties may be used along with the structural modular building system described herein.
As used herein, the term “composite deck” is used to describe the structural deck having concrete poured thereon. Once the concrete is poured onto the corrugation on the structural deck, the nelson studs are attached through the deck to the structural steel beams below. Once the concrete hardens, the nelson studs act to mechanically fasten the concrete within the steel structure forming a composite structural deck allowing the composite deck to share mechanical and engineering properties of both materials.
In general, the embodiments described herein relate to a containerized, transportable, pre-fabricated, pre-assembled, adjustable, structural modular building system for construction of a building comprising a plurality of horizontal structural decks along the x-axis and y-axis and vertical structural steel frames along the z-axis for each module. Each module supports the wet load of concrete for the floor above, and when poured forms a composite deck combining the mechanical and engineering properties of the concrete and steel. The modules' adjustable structural frames act as columns and sheer walls for the building design. The structural modules may be expanded and contracted to vary the height, length, and width of the structural module based on building specifications. In such, the structural modules may be used for buildings having various floor dimensions, and may form self-contained structural elements within the building structure.
The embodiments described herein allow for the structural modules to be stacked upon one another, allowing for multiple floors of a building to be constructed in a single day, rather than the four-day process common employed in the concrete industry. The embodiments also allow for the elimination of the formwork and associated labor thereof commonly used in the arts. The system allows for the structural modules to be easily transported to the building site anywhere in the world using the standard ISO shipping methodologies. Once at the construction site, the structural modules are readily constructed and stacked based on the building requirements.
The system provides a containerized, pre-engineered, and prefabricated system that is engineered and fabricated off-site prior to being shipped to the build site. The system is engineered to the building specifications and may be easily shipped using ISO shipping standards to the build site.
In some embodiments, the structural module components are pre-engineered in view of the building requirements for the particular build (i.e., for a two-floor structure, twenty-floor structure, etc.)
In some embodiments, a plurality of structural frames are dispensed within a single container to optimize the shipping of the system.
One skilled in the arts will readily understand that various numbers of structural frames may be positioned within the container during shipping. In the illustrated example shown in
Each structural module allows for the expansion of the height, width, and length of the structural decks and structural frames. Stacking the structural modules allow for the system to be used for multistory building applications.
In some embodiments, the structural module 100 includes three structural frames 104 at each end. One skilled in the arts will readily understand that various numbers of structural frames 104 may be positioned within a single structural module to optimize shipping of the structural modules.
In some embodiments, the structural frames 104 allow for rapid vertical expansion of the system providing the means to disperse a greater workforce at one time during construction of the structure.
In some embodiments, plumbing, electrical, and the like may be at least partially prefabricated and pre-installed to be included with the containerized structural module 100 before construction of the structure is started to reduce the build time of the structure.
In some embodiments, auxiliary poured concrete may be utilized to assist in carrying the dead load of a fully loaded building structure as well as to act as a shear wall to resist the overturning moment on the structure produced by wind loads.
In some embodiments, each structural frame 104 may lock into position on the track 410 to form a shear wall composed of continuous sequence of structural frames 104. The structural frames 104 may be load-bearing if the structural frames are stacked on top of one another as illustrated in
One skilled in the arts will readily understand that a plurality of structural decks 110 may be stacked vertically on top of one another. The stacked structural decks may facilitate the efficient shipment of the structural module system.
It is to be understood that the structural frames may be oriented in the x-direction and the y-direction.
It is to be understood that the structural frames may be oriented in the y-direction or x-direction on each floor of the structure. The structural frames counteract stresses from the building moment about the y-axis and the x-axis.
In some embodiments, the side decks form the sides of the containerized structural module system to permit the structural module to be shipped by rail, roadway, or by sea.
In some embodiments, each structural module is configured as a self-supporting structure and provides a form for the building when shipped to the build site.
One skilled in the arts will readily understand that the system may be used for smaller building sites, such as a house to permit the prefabricated and pre-engineered structural modules to be shipped to the build site.
In some embodiments, the structural decks may be applied to any structure or building type. For example, the structural decks may be used between two concrete sheer walls where the decks sit on opposing angles to form the floor, thus eliminating the need to stack the structural decks.
In some embodiments, the structural frames may act as a shoring element in a shoring scaffold system.
Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to literally describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and/or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.
An equivalent substitution of two or more elements can be made for any one of the elements in the claims below or that a single element can be substituted for two or more elements in a claim. Although elements can be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination can be directed to a subcombination or variation of a subcombination.
It will be appreciated by persons skilled in the art that the present embodiment is not limited to what has been particularly shown and described hereinabove. A variety of modifications and variations are possible in light of the above teachings without departing from the following claims.
