STRUCTURAL MODULES FOR CONCRETE BUILDING CONSTRUCTION

Abstract

A containerized, transportable, pre-engineered, pre-fabricated, pre-assembled, adjustable, structural modular building system is disclosed, comprising a plurality of structural modules comprising a plurality of horizontal structural decks and vertical structural frames to be used in building construction. The building system is transportable world-wide using existing standardized ISO shipping methodologies of truck, train and shipping vessel. 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. In a single module configuration, the bottom horizontal structural deck is 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 a building module. A track system 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 the each of the bottom deck, the first side deck and the second side deck. A plurality of corrugations affixed to each of the bottom deck, the first side deck, and the second side deck to form a surface whereon concrete is poured.

Claims

1. A containerized, transportable, structural modular building system, comprising: a plurality of pre-engineered, pre-assembled, and adjustable structural modules comprising a plurality of adjustable horizontal structural decks and adjustable vertical structural frames which, when positioned along an x-axis or a y-axis of a structure, resist moments about those axes; a bottom deck of the plurality of horizontal structural decks positioned adjacent to a first side deck of the horizontal structural decks and a second side deck of the horizontal structural decks, the first and second side decks of the horizontal structural decks each rotationally engaged to each side of the bottom deck to form an adjustable structural module of the structural modular building system; a track system slidingly engaged with a plurality of adjustable vertical structural frames and including a locking mechanism to retain the plurality of adjustable vertical structural frames in position along a length of the bottom deck; a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck; and wherein the plurality of corrugated decks are constructed and arranged to form a structural deck constructed and arranged to receive and support the wet load of concrete poured thereon without additional bracing.

2. (canceled)

3. The system of claim 1, wherein the plurality of corrugated decks are anchored to the horizontal deck steel members via a plurality of nelson studs, and wherein the corrugated decks are constructed and arranged to be filled with concrete to form a composite deck.

4. The system of claim 3, further comprising a perimeter forming an anchor for the plurality of nelson studs.

5. The system of claim 4, wherein the perimeter comprises a protrusion to permit the concrete to be poured at a sufficient thickness above the corrugation.

6. The system of claim 5, wherein the plurality of adjustable vertical structural frames are positioned on opposing ends of the bottom deck, the first side deck, and the second side deck.

7. The system of claim 6, wherein the plurality of adjustable vertical structural frames and horizontal structural decks are extendable in the x-direction, the y-direction, and the z-direction.

8. The system of claim 7, wherein each adjustable vertical structural frame of the plurality of adjustable vertical structural frames comprises 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.

9. A structural module system, comprising: a plurality of structural modules comprising a bottom deck positioned adjacent a first side deck and a second side deck, the first and second side decks rotationally engaged to each side of the bottom deck; a track system to slidingly engage with a plurality of adjustable vertical structural frames, the track system including a locking mechanism to retain the plurality of adjustable vertical structural frames in position along a length of the each of the bottom deck, the first side deck and the second side deck; and a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck, the plurality of corrugated decks arranged to form a surface; and wherein the plurality of structural modules are stackable to permit the construction of a multilevel building, wherein the structural module system is pre-engineered and prefabricated prior to shipment.

10. The system of claim 9, wherein the plurality of corrugated decks are anchored to the bottom deck, the first side deck, and the second side deck via a plurality of nelson studs.

11. The system of claim 10, further comprising a perimeter forming an anchor for the plurality of nelson studs.

12. The system of claim 11, wherein the perimeter comprises a protrusion to permit the concrete to be poured at a sufficient thickness above the corrugation.

13. The system of claim 12, wherein the plurality of adjustable vertical structural frames are positioned on opposing ends of the bottom deck, the first side deck, and the second side deck.

14. The system of claim 13, wherein each of the plurality of adjustable vertical structural frames are extendable in at least one of an x-direction, a y-direction, and a z-direction.

15. The system of claim 14, wherein the bottom deck, the first deck, and the second deck are each extendable in at least one of an x-direction or a y-direction.

16. The system of claim 15, further comprising at least one support beam releasably engaged with each of the bottom deck, the first side deck, and the second side deck to distribute the load of the concrete.

17. The system of claim 16, wherein each adjustable vertical structural frame of the plurality of adjustable vertical 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.

18. (canceled)

19. A structural module system, comprising: a plurality of expandable structural modules comprising a bottom deck positioned adjacent a first side deck and a second side deck, the first and second side decks rotationally engaged to each side of the bottom deck; a track system to slidingly engage with a plurality of expandable structural frames, the track system including a locking mechanism to retain the plurality of expandable structural frames in position along a length of the each of the bottom deck, the first side deck and the second side deck; and a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck, the plurality of corrugated decks arranged to form a surface whereon concrete is poured, wherein the plurality of expandable structural modules are configurable in a folded configuration to permit shipping and wherein the plurality of structural modules are stackable in an unfolded configuration to permit the construction of a multilevel building.

20. The system of claim 19, wherein the plurality of corrugated decks are anchored to the bottom deck, the first side deck, and the second side deck via a plurality of nelson studs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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:

[0017] FIG. 1 illustrates a perspective view of the structural module, comprised of a plurality of structural decks and structural frames in a closed, shipping configuration, according to some embodiments;

[0018] FIG. 2 illustrates a perspective view of the structural module with the corrugation removed, according to some embodiments;

[0019] FIG. 3 illustrates a perspective view of the structural module and rotational components, according to some embodiments;

[0020] FIG. 4 illustrates a perspective view of the structural module in an unfolded configuration having a plurality of tracks to allow movement of the vertical structural frames on the horizontal structural decks, according to some embodiments;

[0021] FIG. 5 illustrates a detail view of the tracks on the horizontal structural decks, according to some embodiments;

[0022] FIG. 6 illustrates a perspective view of the structural module comprising a plurality of horizontal structural decks and vertical structural frames, according to some embodiments;

[0023] FIG. 7 illustrates a perspective view of the structural frames in the collapsed position, according to some embodiments;

[0024] FIG. 8 illustrates a perspective view of the structural frames expanded in the x-direction and the z-direction, according to some embodiments;

[0025] FIG. 9 illustrates a perspective view of the expanded structural frames rotated 90 degrees, according to some embodiments;

[0026] FIG. 10 illustrates a perspective view of the structural modules in a collapsed configuration such that the horizontal structural decks are expanded in an x-direction and the y-direction and the vertical structural frames are expanded in the x-direction and the z-direction, according to some embodiments;

[0027] FIG. 11 illustrates a perspective view of the structural deck in a closed position with arrows indicating the expansion into the x-direction, according to some embodiments;

[0028] FIG. 12 illustrates a perspective view of the structural deck expanded to the x-direction, according to some embodiments;

[0029] FIG. 13 illustrates a perspective view of the structural deck in a closed position with arrows indicating the expansion into the y-direction, according to some embodiments;

[0030] FIG. 14 illustrates a perspective view of the structural deck expanded to the y-direction, according to some embodiments;

[0031] FIG. 15 illustrates a perspective view of the structural deck expanded in the x-direction with the structural frames rotated 90 degrees with the attached structural frames being expanded in the x-direction, according to some embodiments;

[0032] FIG. 16 illustrates a perspective view of the horizontal structural deck expanded in the x-direction with the attached structural frames expanded in the x-direction and the z-direction, according to some embodiments;

[0033] FIG. 17 illustrates a perspective view of the horizontal structural deck, expanded in the x-direction, attached structural frames, expanded in the x-direction and z-direction, and corrugation, according to some embodiments;

[0034] FIG. 18 illustrates a detail view of the corrugation installed with a nelson stud, according to some embodiments;

[0035] FIG. 19 illustrates a detail view of the plurality of structural beam, perimeter angle, corrugated deck and nelson studs, according to some embodiments;

[0036] FIG. 20 illustrates a perspective view of the stacked expanded structural modules, according to some embodiments; and

[0037] FIG. 21 illustrates a perspective view of the stacked structural modules with various positioning, according to some embodiments.

DETAILED DESCRIPTION

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] FIG. 1 illustrates the containerized structural module 100 and corrugation 102 which is configured to meet ISO shipping standards for various shipping methods including by truck, railway, and shipping vessels. The structural module is containerized having all necessary components to be optionally expanded, contracted, and constructed at the build site where it is shipped. Each structural module comprises a plurality of structural frames 104 arranged at the first end 106 and second end 108 of the structural module 100. The structural frames 104 are retained between a bottom deck 110 and first and second side decks 112,114. The corrugation 102 may be arranged to form the sidewalls on each side 116, 118, 120, 122, 124, 126 of the structural module 100. During shipping, the structural elements, including the structural frames 104 and decks 110, 112, 114, are arranged in a folded configuration to meet ISO shipping standards.

[0051] 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.)

[0052] In some embodiments, a plurality of structural frames are dispensed within a single container to optimize the shipping of the system.

[0053] FIG. 2 illustrates the structural module 100 having the corrugation removed to illustrate the components. In some embodiments, a plurality of vertical structural frames 104 are positioned on each side 116, 118 of the structural module 100 having corresponding dimensions to the bottom deck 110 and side decks 112,114. In some embodiments, to meet ISO standards, the dimensions are 8-feet wide (x-direction), 8-feet 6-inches tall (z-direction) and 40-feet long (y-direction) to permit the structural module 100 to be shipped to the building site. One skilled in the arts will readily understand that various ISO shipping standard dimensions may be used, including high-cube, and 20-foot container sizes. In some embodiments, intermodal containers may be utilized.

[0054] 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 FIG. 2, three structural frames are provided. However, it is to be understood that additional structural frames may be provided.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] FIG. 3 illustrates the structural module 100 and the rotation of the side decks 112,114 to a flattened position (as illustrated in FIG. 4) to form the building module. The side decks 112,114 may rotate via a hinge, bolt, or similar component to allow for the flattened building module wherein one configuration, the user slides the structural frames onto the building module via a track system.

[0061] FIG. 4 illustrates the building module 400 in a flattened configuration having a plurality of tracks 410 to permit the user to slide or otherwise move the structural frames into a suitable position based on the building specifications. The tracks 410 extend at least partially along the length of the side decks 112, 114 to allow the user to readily position the structural frames along the length of the side decks 112,114.

[0062] FIG. 5 illustrates a detail view of the tracks 410 positioned on the bottom deck 110 to provide a means for the structural frames to slide thereon when no hoisting is available. Each track 410 is configured to receive the structural frames and allow for the structural frames to disengage with the structural module. In some embodiments, the tracks may have a moving element such as rollers, a bearing system, or other component to facilitate the movement of the structural frame along the length of the bottom deck 110 and/or side decks 112,114.

[0063] FIG. 6 illustrates the structural frames 104 engaged with the tracks 410 while the side decks 112,114 are folded into a flat configuration. In some embodiments, each structural frame 104 is engaged with the track 410 by sliding from the ends 420,430 of the building module at least partially towards the central portion 440. The structural frames 104 extend perpendicular to the plane of the unfolded bottom deck 110 and side decks 112,114.

[0064] 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 FIG. 19 and FIG. 20.

[0065] FIGS. 7-9 illustrate the vertical structural frame 104 in an exemplary embodiment. Each structural frame 104 includes a top beam 800, bottom beam 802, left beam 804, and right beam 806 arranged in a geometric shape forming the sides of the shape (such as a square, rectangle, etc.) depending on building specifications. First and second supports 808,810 (see FIG. 7) are positioned on the bottom beam 802. Each beam of the structural frame 104 is extendable to permit the extension of the beams in the x and/or z-directions.[Structural frame once expanded can be oriented along either the x or y axis] The extension of the beams within the vertical structural frame allows the structural module to accommodate various building dimensions while retaining the ability to collapse into ISO standard dimensions for shipping. Each vertical structural frame 104 includes internal sections 812,814,816,818 (shown in FIG. 7) which slide along the exterior frame, which forms a conduit to extend the dimensions of the structural frame 104. Specifically, FIG. 7 illustrates the structural frame 104 in a collapsed configuration. FIG. 8 illustrates the structural frame 104 extended in the x-direction and the z-directions. FIG. 9 illustrates the structural frame 104 rotated on a side which may be used for various building dimension specifications.

[0066] FIG. 10 illustrates the structural module 100 in an unfolded configuration having a first left frame 1002, second left frame 1004, first center frame 1006, second center frame 1008, first right frame 1010, and second right frame 1012 engaged with the track system. The unfolded structural module 100 provides a building deck 1014 whereon each of the structural frames are aligned along the beams of the structural module deck to form a shear wall in the x or y direction to resist building moments along those axis.

[0067] FIG. 11 illustrates the structural deck 110 (which may also include side decks 112,114 described hereinabove) expanded in the x-direction. A plurality of support beams 1102 are arranged to distribute loads placed on the structural deck 110 when in an expanded position. Each support beam 1102 may be releasably engaged with the structural deck 110 depending on building specifications. The support beam 1204 may be slidingly engaged with the structural deck 110 or may be fixed in position via bolts, by welding or by similar attachment mechanism.

[0068] 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.

[0069] FIG. 12 illustrates the structural deck 110 in an expanded configuration wherein the distance between the left beam 1202 and right beam 1204 is increased. Due to the increase in distance, support beams 1102 are positioned along the front and rear beams 1206,1208 to distribute the load placed on the structural deck 110. FIG. 13 illustrates the structural deck which may be expanded in the y-direction depending on the building specifications. To modulate the dimensions of the structural deck 110, sliding members are moved to expand or contract each structural deck. One skilled in the arts will readily understand that the structural decks may be expanded in the x,y, and the structural frames may be expanded in the x or z-directions based on building specifications. FIG. 14 illustrates the structural deck 110 in an expanded configuration.

[0070] FIG. 15 and FIG. 16 illustrate the expandable structural decks of the structural module 100. In specific reference to, FIG. 15, the structural frames 104 are rotated 90° to accommodate building specifications with the structural decks expanded in the x-direction. One skilled in the arts will readily understand that a plurality of structural modules 100 may be used in series to expand the size of the structure being built.

[0071] It is to be understood that the structural frames may be oriented in the x-direction and the y-direction.

[0072] FIG. 17 illustrates the structural module 100 having corrugation 102 positioned on the structural decks 110,112,114. For example, the corrugation is a corrugated metal deck which is affixed to the structural module to provide a surface for the concrete to be poured on. The corrugation 102 covers the structural decks 110,112,114 to prevent the flow of concrete therethrough.

[0073] FIG. 18 illustrates a detail view of the attachment system 1702 for the corrugation 102. In one example, the corrugation 102 is anchored to the structural module via a nelson stud to retain the corrugation 102 in a suitable position. FIG. 19 illustrates the nelson stud 1802 positioned through the corrugation 102 to retain it at the perimeter 1804 of the structural decks. The perimeter 1804 has a protrusion 1806 to secure the corrugation in position. In some embodiments, the perimeter 1804 retains the concrete when poured onto the structural decks to allow for the concrete to be poured at a sufficient level in view of the building specifications.

[0074] FIG. 20 and FIG. 21 illustrate the structural module system 1900 having a plurality of structural module 100 arranged to construct a multilevel building 1902. As illustrated, the structural modules 100 may be arranged to stack atop one another, as well as positioned at the ends or sides of each other depending on building specifications. FIG. 21 in particular illustrates the ability of structural modules 100 to be adjusted to create or correspond to a building profile. This may be especially useful when creating balconies, patios, or for creating a building with a dynamic facade.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] In some embodiments, the structural frames may act as a shoring element in a shoring scaffold system.

[0081] 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.

[0082] 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.

[0083] 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.