Floor Assembly

Abstract

In one embodiment, a floor assembly includes a first perimeter joist including a first length with first and second ends; a second perimeter joist including a second length with third and fourth ends; a third perimeter joist including a third length with fifth and sixth ends; and a fourth perimeter joist including a fourth length with seventh and eighth ends. The first and fourth perimeter joists are secured to each other at the first and eighth ends with one or more welds. The first and second perimeter joists are secured to each other at the second and third ends with one or more welds. The second and third perimeter joists are secured to each other at the fourth and fifth ends with one or more welds.

Claims

1. A floor assembly comprising: a first perimeter joist comprising a first length with a first end and a second end; a second perimeter joist comprising a second length with a third end and a fourth end; a third perimeter joist comprising a third length with a fifth end and a sixth end; and a fourth perimeter joist comprising a fourth length with a seventh end and an eighth end; wherein: the first and fourth perimeter joists are secured to each other at the first and eighth ends with one or more welds; the first and second perimeter joists are secured to each other at the second and third ends with one or more welds; the second and third perimeter joists are secured to each other at the fourth and fifth ends with one or more welds; the third and fourth perimeter joists are secured to each other at the sixth and seventh ends with one or more welds; and the first, second, third, and fourth perimeter joists are configured to be welded to embed plates in piers of a foundation.

2. The floor assembly of claim 1, further comprising: a first gusset at a first corner formed by the first and fourth perimeter joists where they are secured to each other, wherein the first gusset is secured to the first and fourth perimeter joists with one or more welds; a second gusset at a second corner formed by the first and second perimeter joists where they are secured to each other, wherein the second gusset is secured to the first and second perimeter joists with one or more welds; a third gusset at a third corner formed by the second and third perimeter joists where they are secured to each other, wherein the third gusset is secured to the second and third perimeter joists with one or more welds; and a fourth gusset at a fourth corner formed by the third and fourth perimeter joists where they are secured to each other, wherein the fourth gusset is secured to the third and fourth perimeter joists with one or welds.

3. The floor assembly of claim 2, wherein the gussets comprise steel and are triangular in shape.

4. The floor assembly of claim 1, further comprising one or more cross members that each comprise a fifth length with a ninth end and a tenth end, wherein: the fifth length is substantially parallel to the lengths of the second and fourth perimeter joists; and the ninth end is secured to the first perimeter joist with one or more welds and the tenth end is secured to the third perimeter joist with one or more welds.

5. The floor assembly of claim 4, wherein each of one or more of the cross members comprises a continuous C-channel beam comprising American Society for Testing and Materials (ASTM) A992 steel.

6. The floor assembly of claim 1, further comprising one or more brace members that each comprise a sixth length with an eleventh end and a twelfth end, wherein: the sixth length is substantially parallel to the lengths of the second and fourth perimeter joists; and the eleventh end is secured to the first perimeter joist with one or more welds and the twelfth ends is secured to the third perimeter joist with one or more welds.

7. The floor assembly of claim 6, wherein each of one or more of the brace members is a continuous steel C-channel beam.

8. The floor assembly of claim 1, further comprising: a pan spanning an interior of the floor assembly; and concrete set in the pan.

9. The floor assembly of claim 8, wherein the pan: is supported by one or more cross members in the floor assembly; and is secured to one or more of the cross members with one or more welds.

10. The floor assembly of claim 8, wherein: the pan comprises a 22-gauge 2 composite steel deck; and the concrete is lightweight concrete, has a total slab depth of approximately 4, and is reinforced with a wire mesh.

11. The floor assembly of claim 8, further comprising one or more pour stops secured to one or more of the perimeter joists and configured to contain the concrete within an interior area of the floor assembly when the concrete is poured.

12. The floor assembly of claim 11, wherein one or more of the pour stops are positioned to create when one or more leaveouts when the floor assembly is mated to another floor assembly.

13. The floor assembly of claim 1, wherein the floor assembly is part of a pre-fabricated or modular home.

14. The floor assembly of claim 1, wherein each of the perimeter joists is a continuous steel C-channel beam.

15. The floor assembly of claim 1, wherein: the first and third lengths are approximately equal to each other and greater than the second and fourth lengths; and the second and fourth lengths are approximately equal to each other and less than the first and third lengths.

16. The floor assembly of claim 1, wherein: the first and third perimeter joists comprise channels that face an interior of the floor assembly; and the second and fourth perimeter joists comprise channels that face an exterior of the floor assembly.

17. The floor assembly of claim 1, wherein the piers comprise helical piers.

18. A building comprising: a floor assembly comprising: a first perimeter joist comprising a first length with a first end and a second end; a second perimeter joist comprising a second length with a third end and a fourth end; a third perimeter joist comprising a third length with a fifth end and a sixth end; and a fourth perimeter joist comprising a fourth length with a seventh end and an eighth end; wherein: the first and fourth perimeter joists are secured to each other at the first and eighth ends with one or more welds; the first and second perimeter joists are secured to each other at the second and third ends with one or more welds; the second and third perimeter joists are secured to each other at the fourth and fifth ends with one or more welds; and the third and fourth perimeter joists are secured to each other at the sixth and seventh ends with one or more welds; a foundation comprising a plurality of piers comprising embed plates, wherein the first, second, third, and fourth perimeter joists are welded to at least some of the embed plates of at least some of the piers of the foundation.

19. The building of claim 18, wherein at least some of the piers comprise helical piers.

20. The building of claim 1, wherein the floor assembly further comprises: a first gusset at a first corner formed by the first and fourth perimeter joists where they are secured to each other, wherein the first gusset is secured to the first and fourth perimeter joists with one or more welds; a second gusset at a second corner formed by the first and second perimeter joists where they are secured to each other, wherein the second gusset is secured to the first and second perimeter joists with one or more welds; a third gusset at a third corner formed by the second and third perimeter joists where they are secured to each other, wherein the third gusset is secured to the second and third perimeter joists with one or more welds; a fourth gusset at a fourth corner formed by the third and fourth perimeter joists where they are secured to each other, wherein the fourth gusset is secured to the third and fourth perimeter joists with one or welds; one or more cross members that each comprise a fifth length with a ninth end and a tenth end, wherein: the fifth length is substantially parallel to the lengths of the second and fourth perimeter joists; and the ninth end is secured to the first perimeter joist with one or more welds and the tenth end is secured to the third perimeter joist with one or more welds. one or more brace members that each comprise a sixth length with an eleventh end and a twelfth end, wherein: the sixth length is substantially parallel to the lengths of the second and fourth perimeter joists; and the eleventh end is secured to the first perimeter joist with one or more welds and the twelfth ends is secured to the third perimeter joist with one or more welds; a pan spanning an interior of the floor assembly, wherein in the pan is supported by one or more of the cross members and secured to one or more of the cross members with one or more welds; and concrete set in the pan.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 illustrates an example portion of an example modular or pre-fabricated home installed at an example home site.

[0005] FIG. 2 illustrates an example portion of an example floor supporting an example wall.

[0006] FIG. 3 illustrates an example portion of an example floor set on an example foundation and supporting an example wall.

[0007] FIG. 4 illustrates example floors mated to each other.

[0008] FIGS. 5A-5B illustrates example mating of example floors.

[0009] FIGS. 6A-6B illustrate example thresholds between example floors.

[0010] FIGS. 7A-7K illustrate example details of example floors.

[0011] FIG. 8 illustrates an example method for constructing a modular or pre-fabricated home.

[0012] FIG. 9 illustrates an example method for installing a modular or pre-fabricated home.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0013] Particular embodiments provide systems and methods for more efficiently or effectively strengthening the floor of a modular or pre-fabricated home or other building, which may reduce or eliminate damage to the floor from strains placed on it, for example, by being loaded onto a vehicle for transportation, being transported to a home site, being unloading at the home site, or being installed at the home site. In addition or as an alternative, particular embodiments may reduce the cost of construction of the home or reduce the cost of installation of the home at the home site. In addition or as an alternative, particular embodiments may reduce the pouring or setting of concrete at the home site. In addition or as an alternative, particular embodiments may focus warranties and repairs on the foundation of the home to steel, welds, and piers, which may be beneficial to the builder. Although modular or pre-fabricated homes are described and illustrated herein, this disclosure contemplates any suitable buildings constructed in any suitable ways. Reference herein to a home may include a garage, hangar, or other building, and vice versa, where appropriate. Although particular embodiments are described and illustrated herein as improving floors of particular buildings, this disclosure contemplates such embodiments improving any suitable components or systems of any suitable buildings. A floor may include one or more floors, subfloors, foundations, portions of the foregoing, or a combination of the foregoing, where appropriate. Although particular floors are described and illustrated herein, this disclosure contemplates any suitable floors.

[0014] FIG. 1, which is not necessarily to scale, illustrates an example portion 100 of an example modular or pre-fabricated home installed an at an example home site. FIG. 1 provides an elevation view of a cross section of portion 100 of the home. The home includes one or more roofs 102, ceilings 104, walls 106, and floors 108 and is secured to one or more foundations 110. The home (or portion 100 of the home) may include one or more components or systems other than (in addition or as an alternative to) those described or illustrated herein. In addition, in particular embodiments, a roof 102, ceiling 104, wall 106, floor 108, or foundation 110 may include one or more components or subsystems other than (in addition or as an alternative to) those described or illustrated herein. Although a particular home with particular components and systems is described and illustrated, this disclosure contemplates any suitable home or other building with any suitable components or systems. One or more portions of the home may be constructed and assembled at a factory and then transported to the home site for installation. For example, roof 102 may be constructed at the factory and transported to the home site. In addition, ceiling 104 (or a temporary ceiling), walls 106, and floor 108 may be constructed and assembled at the factory and transported as a single unit to the home site, where they may be set onto and secured to one or more foundations 110. Roof 102 may also be set and secured to the tops of walls 106 or ceiling 104 at the home site. In addition or as an alternative, all or one or more portions of roof 102 may be constructed or assembled at the home site. Although particular construction, assembly, transportation, and installation are described and illustrated herein, this disclosure contemplates any suitable construction, assembly, transportation, and installation.

[0015] Roof 102 may include a standing seam metal roof 112 with an underlayment 114 (which may be oriented strand board (OSB) or plywood), a thermal barrier 116 (which may be 10 open-cell spray foam), trusses 118, and an eave drip or rake 120. Although a particular roof is described and illustrated herein, this disclosure contemplates any suitable roofs. Ceiling 104 may include a drywall ceiling set on one or more double-top plates on walls 106. Although a particular ceiling is described and illustrated herein, this disclosure contemplates any suitable ceilings. Wall 106 may include drywall or gypsum board on the interior, R19 fiberglass insulation, wall framing, and R-6.6 sheathing on the exterior and may be set on one or more bottom plates on floor 108. An exterior finish may be applied to wall 106 at the home site. Although a particular wall is described and illustrated herein, this disclosure contemplates any suitable walls. Foundation 110 may include any suitable number of piers (which may be helical piers) set on foundation footings in the ground. In addition, the inside perimeter of foundation 110 may be covered with foam or other insulation. Although a particular foundation is described and illustrated herein, this disclosure contemplates any suitable foundations. Reference herein to a foundation may include a portion of a foundation, and vice versa, where appropriate. Floor 108 may include concrete 122 set in a deck or pan 124 set on cross members (which are not shown in FIG. 1) and perimeter joists 126, as described further below. In particular embodiments, by way of example only, concrete 122 may be lightweight concrete, have a total slab depth of approximately 4, and be reinforced with 66-W1.4W1.4 welded wire mesh, as described further below. In particular embodiments, by way of example only, pan 124 may be a 22-gauge minimum 2 composite metal deck. Perimeter joists 126 may be horizontal structural members used to frame or span floor 108 and may provide stiffness to floor 108. Perimeter joists 126 may also support pan 124 and concrete 122. A perimeter joist 126 may be a continuous steel C-channel beam. Cross members may be horizontal structural members used to span the width of floor 108 and may also provide stiffness to floor 108. Cross members may also support pan 124 and concrete 122. A cross member may be made of steel or another suitable material. Floor 108 may also include one or more brace members (which are not shown in FIG. 1), which may be horizontal structural members used to span the width of floor 108 and provide stiffness to floor 108. Brace members may be made of steel or another suitable material.

[0016] Floor 108 may be secured to foundation 110 by welding one or more portions of one or more perimeter joists 126 of floor 108 to one or more embed plates on top of foundation 110, as described further below. Although a particular floor secured in a particular way to a particular foundation is described and illustrated herein, this disclosure contemplates any suitable floor secured in any suitable way to any suitable foundation. Components, elements, and systems illustrated in and described with reference to FIG. 1 may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0017] FIG. 2, which is not necessarily to scale, illustrates an example portion of an example floor 108a supporting an example wall 106a. FIG. 2 provides an elevation view of a cross section of those portions of wall 106a and floor 108a. In the example of FIG. 2, wall 106a includes typical wall framing and insulation with gypsum board on the interior and wall sheathing on the exterior. The gypsum board may be gypsum board. The wall sheathing may be 7/16 ZIP System R-sheathing. Wall 106a also includes a 26 treated bottom plate 128a, which is secured to a 24 treated bottom plate 132a of floor 108a. Barrier sealant may be applied to the underside of bottom plate 128a. As indicated by reference number 130a, the wall sheathing of wall 106a extends down to approximately 1 from the bottom of perimeter joist 126a of floor 108a. Floor 108a includes concrete 122a set in a pan 124a, perimeter joist 126a, bottom plate 132a, a cross member 134a, and a metal (e.g. steel) plate (or tongue) 136a used to secure perimeter joist 126a to cross member 134a, which may both be welded to plate 136a. Concrete 122a may be lightweight concrete and have a total slab depth of approximately 4. Pan 124a may be a composite deck. Pan 124a may be supported by cross member 134a (and by other cross members 134 not shown in FIG. 2). Cross member 134a may be a steel channel cross member. Perimeter joist 126a has an exterior-facing channel covered by a steel plate 152a welded in place. Perimeter joist 126a may be a continuous steel channel rim joist. Components, elements, and systems illustrated in and described with reference to FIG. 2 may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0018] FIG. 3, which is not necessarily to scale, illustrates an example portion of an example floor 108b set on an example foundation 110a and supporting an example wall 106b. FIG. 3 provides an elevation view of a cross section of those portions of wall 106b, floor 108b, and foundation 110a. In the example of FIG. 3, wall 106b includes typical wall framing with gypsum board on the interior and wall sheathing on the exterior. Wall 106b also includes a 26 treated bottom plate 128b, which is secured to a 24 treated bottom plate 132b of floor 108b. As indicated by reference number 130b, the wall sheathing of wall 106b extends down to approximately 1 from the bottom of a perimeter joist 126b of floor 108b. Foundation 110a includes a metal (e.g. steel) embed plate 138 embedded in a pier (which may be a helical pier) set on a foundation footing in the ground. Floor 108b includes concrete 122b set in a pan 124b, perimeter joist 126b, bottom plate 132b, a cross member 134b, and a metal plate 136b used to secure perimeter joist 126b to cross member 134b, which may both be welded to plate 136b. Perimeter joist 126b has an interior-facing channel and is welded to embed plate 138 to secure floor 108b to foundation 110a. There may be an approximately 1 overhang between the exterior edge of perimeter joist 126b and the exterior edge of foundation 110a. Components, elements, and systems illustrated in and described with reference to FIG. 3 may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0019] FIG. 4, which is not necessarily to scale, illustrates example floors 108a, 108b, and 108c mated to each other. FIG. 4 provides a plan view of a cross section of floors 108a, 108b, and 108c. The home in FIG. 1 may include floors 108a, 108b, and 108c. The combination of perimeter joists 126, cross members 134, brace members 140, and gussets 142 illustrated in FIG. 4 (and as illustrated in and described with reference to other figures herein) may in particular embodiments more efficiently or effectively strengthen floors 108a, 108b, and 108c, which may reduce or eliminate damage to floors 108a, 108b, and 108c (and one or other components or systems of the home) from strains placed on them, for example, by being loaded onto a vehicle for transportation, being transported to a home site, being unloading at the home site, or being installed at the home site. In addition or as an alternative, this combination may in particular embodiments reduce the cost of construction of the home or reduce the cost of its installation at the home site.

[0020] Floor 108c is mated to floors 108d and 108e. Floor 108c may be approximately 40 5175, floor 108d may be approximately 395175, and floor 108e may be approximately 235175. Although particular floors with particular dimensions are described and illustrated herein, this disclosure contemplates any suitable floors with any suitable dimensions. Floor 108c includes perimeter joists 126c-126f, cross members 134c-134k, brace members 140a and 140b, and gussets 142a-142d. Floor 108d includes perimeter joists 126g-126j, cross members 134l-134s, brace members 140c and 140d, and gussets 142e-142h. Floor 108e includes perimeter joists 126k-126n, cross members 134t-134w, brace member 140e, and gussets 142i-142l. Each of floors 108c, 108d, and 108e also includes concrete 122 set in a pan 124 (which are not shown in FIG. 4) spanning its area. A pan 124 may be secured to one or more perimeter joists 126, cross members 134, or brace members 140 with approximately arc spot welds, where appropriate. In particular embodiments, by way of example only, a perimeter joist 126 may be a C1220.7 steel channel rim; a cross member 134 may be a C818.75 steel cross member or two side-by-side C818.75 steel cross members (e.g. cross members 134o, 134p, and 134w); a brace member 140 may be a C613 steel brace members; and a gusset 142 may be a 1212 triangle gusset or a 1212 angle gusset plate. Gussets 142 may be triangular plates or brackets used to strengthen angles in the framing of a floor 108. A gusset 142 may be made of steel or another suitable material. Perimeter joists 126, cross members 134, brace members 140, and gussets 142 may be welded to each other where appropriate. For example, a gusset 142 may be welded to two adjoining perimeter joists 126. In addition or as an alternative, adjoining perimeter joists 126 may be welded to each other where they meet. A cross member 134 or brace member 140 may also be welded to a perimeter joist 126 where they meet, e.g., using a metal plate, as described further below.

[0021] As described above, a perimeter joist 126 may be a continuous steel C-channel beam with an exterior-or interior-facing channel. In particular embodiments, the channels of perimeter joists 126 that are perpendicular to cross members 134 and brace members 140 within a floor 180 may be interior facing and the channels of perimeter joists 126 that are parallel to cross members 134 and brace members 140 within a floor 180 may be exterior facing. For example, the channels of perimeter joists 126c, 126e, 126g, 126i, 126k, and 126m may be interior facing and the channels of perimeter joists 126d, 126f, 126h, 126j, 126l, and 126n may be exterior facing. Perimeter joists 126, cross members 134, and brace members 140 may have any suitable spacing within a floor 108. For example, within floor 108c, there may be a distance of approximately 42 between the longitudinal centerlines of perimeter joist 126f and cross member 134c, a distance of approximately 40 between the longitudinal centerlines of cross members 134c and 134d, a distance of approximately 40 between the longitudinal centerlines of cross members 134d and 134e, a distance of approximately 40 between the longitudinal centerlines of cross members 134e and 134f, a distance of approximately 40 between the longitudinal centerlines of cross members 134f and 134g, a distance of approximately 40 between the longitudinal centerlines of cross members 134g and 134h, a distance of approximately 40 between the longitudinal centerlines of cross members 134h and 134i, a distance of approximately 40 between the longitudinal centerlines of cross members 134i and 134j, a distance of approximately 40 between the longitudinal centerlines of cross members 134j and 134k, a distance of approximately 42 between the longitudinal centerlines of perimeter joist 126d and cross member 134k, a distance of approximately 140 between the longitudinal centerlines of perimeter joist 126f and brace member 140a, a distance of approximately 125 between the longitudinal centerlines of brace members 140a and 140b, and a distance of approximately 140 between the longitudinal centerlines of perimeter joist 126d and brace member 140b. Within floor 108d, there may be a distance of approximately 42 between the longitudinal centerlines of perimeter joist 126j and cross member 134l, a distance of approximately 41 between the longitudinal centerlines of cross members 134l and 134m, a distance of approximately 41 between the longitudinal centerlines of cross members 134m and 134n, a distance of approximately 43 between the longitudinal centerlines of cross members 134n and 134o, a distance of approximately 60 between the longitudinal centerlines of cross members 134o and 134p, a distance of approximately 42 between the longitudinal centerlines of cross members 134p and 134q, a distance of approximately 42 between the longitudinal centerlines of cross members 134q and 134r, a distance of approximately 42 between the longitudinal centerlines of cross members 134r and 134s, a distance of approximately 43 between the longitudinal centerlines of perimeter joist 126h and cross member 134s, a distance of approximately 1311 between the longitudinal centerlines of perimeter joist 126j and brace member 140c, a distance of approximately 117 between the longitudinal centerlines of brace members 140c and 140d, and a distance of approximately 1311 between the longitudinal centerlines of perimeter joist 126h and brace member 140d. Within floor 108e, there may be a distance of approximately 43 between the longitudinal centerlines of perimeter joist 126n and cross member 134t, a distance of approximately 43 between the longitudinal centerlines of cross members 134t and 134u, a distance of approximately 43 between the longitudinal centerlines of cross members 134u and 134v, a distance of approximately 43 between the longitudinal centerlines of cross members 134v and 134w, a distance of approximately 65 between the longitudinal centerlines of perimeter joist 126l and cross member 134w, a distance of approximately 118 between the longitudinal centerlines of perimeter joist 126n and brace member 140e, and a distance of approximately 118 between the longitudinal centerlines of perimeter joist 126l and brace member 140e. Although particular spacings within particular floors are described and illustrated herein, this disclosure contemplates any suitable spacings within any suitable floors. Components, elements, and systems illustrated in and described with reference to FIG. 4 may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0022] FIGS. 5A-5B, which are not necessarily to scale, illustrate example mating of example floors 108f and 108g. FIG. 5A provides an elevation view of a cross section of portions of floors 108f and 108g and walls 106c and 106d. FIG. 5B provides an elevation view of a perimeter joist 126o of floor 108f rotated 90 with respect to FIG. 5A. In the example of FIGS. 5A-5B, floor 108f is mated with floor 108g and wall 106c abuts wall 106d. Wall 106c includes a 26 treated bottom plate 128c, and wall 106d includes a 26 treated bottom plate 128d. Floor 108f includes concrete 122c set in a pan 124c, perimeter joist 126o, and a 24 treated bottom plate 132c. In floor 108f, concrete 122c is reinforced with a wire mesh 144a (which may be a 66-W1.4W1.4 wire mesh welded in places to pan 124c). In addition, floor 108f includes a pour stop 146a, which helps to contain concrete 122c in pan 124c when concrete 122c is poured, e.g., at a factory. Pour stop 146a may be a minimum 20-gauge Z-closure pour stop extending a minimum of 2 over a top flange of perimeter joist 126o. FIG. 7E, described more fully below, illustrates an example pour stop 146i similar to pour stops 146a. Bottom plate 132c may also help to contain concrete 122c in pan 124c (or at least that portion of concrete 122c above perimeter joist 126o) when concrete 122c is poured. Similarly, floor 108g includes concrete 122d set in a pan 124d, a perimeter joist 126p, and a 24 treated bottom plate 132d. In floor 108g, concrete 122d is reinforced with a wire mesh 144b (which may also be a 66-W1.4W1.4 wire mesh welded in places to pan 124d). In addition, floor 108g includes pour stop 146b, which helps to contain concrete 122d in pan 124d when concrete 122d is poured. Pour stop 146b may be a minimum 20-gauge Z-closure pour stop extending a minimum of 2 over a top flange of perimeter joist 126p. FIG. 7E, described more fully below, illustrates an example pour stop 146i similar to pour stops 146b. Bottom plate 132d may also help to contain concrete 122d in pan 124d (or at least that portion of concrete 122d above perimeter joist 126p) when concrete 122d is poured. Floor 108f may be mated with floor 108g using bolts, nuts, and washers 148 approximately every 48 along perimeter joists 126o and 126p. The bolts may be through bolts. One of perimeter joists 126o or 126p may include approximately 13/16 round holes and the other one of perimeter joists 126o or 126p may include oversized horizontally slotted holes every 48 along their lengths to receive the bolts. Components, elements, and systems illustrated in and described with reference to FIGS. 5A-5B may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0023] FIGS. 6A-6B, which are not necessarily to scale, illustrate example thresholds between example floors 108h and 108i and between example floors 108j and 108k. In particular embodiments, a threshold may be a region where two floors 108 are mated or otherwise adjacent to each other without one or more walls, e.g., where there is a door or other opening between two rooms or other areas defined by floors 108 (such as, for example, between the areas above floors 108c and 108d or between the areas above floors 108c and 108e in FIG. 4). In the example of FIG. 6A, floor 108h is mated with floor 108i. Floor 108h includes concrete 122e set in a pan 124e and reinforced with a wire mesh 144c; perimeter joist 126q; and pour stop 146c, which helps to contain concrete 122e in pan 124e when concrete 122e is poured. Pour stop 146c may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is approximately 1 inside the exterior edge of perimeter joist 126q. Similarly, floor 108i includes concrete 122f set in pan 124f and reinforced with wire mesh 144d; perimeter joist 126r; and pour stop 146d, which helps to contain concrete 122f in pan 124f when concrete 122f is poured Pour stop 146d may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is approximately 1 from the exterior edge of perimeter joist 126r. FIG. 7C, described more fully below, illustrates an example pour stop 146g similar to pour stops 146c and 146d. The placement of pour stops 146c and 146d on perimeter joists 126q and 126r, respectively, leaves an approximately 2 gap, or leaveout 150, between floors 108h and 108i (above perimeter joists 126q and 126r) when floors 108h and 108i are mated to each other. In particular embodiments, leaveout 150 may be an open space between portions of floors 108h and 108i that may be filled at the home site during installation, and floors 108h and 108i may be constructed such that leaveout 150 is present when floors 108h and 108i are mated to each other. Leaveout 150 may be filled with non-shrink grout or an equivalent levelling compound at the home site during installation. This may facilitate levelling floors 108h and 108i with each other or smoothing unevenness between them, which may avoid the creation of a tripping hazard. Although a particular leaveout with particular dimensions is described and illustrated herein, this disclosure contemplates any suitable leaveout with any suitable dimensions.

[0024] In the example of FIG. 6B, floor 108j is mated with floor 108k. Floor 108j includes concrete 122g set in pan 124g and reinforced with wire mesh 144e; perimeter joist 126s; and pour stop 146e, which helps to contain concrete 122g in pan 124g when concrete 122g is poured. Pour stop 146e may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is substantially flush with the exterior edge of perimeter joist 126s. Similarly, floor 108k includes concrete 122h set in pan 124h and reinforced with wire mesh 144f; perimeter joist 126t; and pour stop 146f, which helps to contain concrete 122h in pan 124h when concrete 122h is poured. Pour stop 146f may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is substantially flush with the exterior edge of perimeter joist 126t. The placement of pour stops 146e and 146f on perimeter joists 126s and 126t, respectively, no gap, or leaveout, between floors 108j and 108k (above perimeter joists 126s and 126t) when floors 108j and 108k are mated to each other. A gasket (which is not shown in FIG. 6B) may be placed in or on the seam between pour stops 146e and 146f, as appropriate. Components, elements, and systems illustrated in and described with reference to FIGS. 6A-6B may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein.

[0025] FIGS. 7A-7K, which are not necessarily to scale, illustrate details of example floors. Components, elements, and systems illustrated in and described with reference to FIGS. 7A-7K may, but need not necessarily, in one or more respects (including but not limited to their design, construction, and relative positioning) be the same as or similar to similarly referenced components, elements, and systems illustrated in or described with reference to other figures herein. FIG. 7A, which provides a plan view, illustrates an example gusset 142m with example dimensions. Gusset 142m may be made of metal (e.g. steel) and, in addition to the dimensions shown, may be approximately thick. FIG. 7B (which provides an elevation view of a cross section) illustrates an example gusset 142n welded to perimeter joists 126u and 126v. By way of example only, perimeter joist 126u may be perimeter joist 126c, 126g, or 126k; perimeter joist 126v may be perimeter joist 126f, 126j, or 126n; gusset 142n may be gusset 142d, 142h, or 142l. Perimeter joist 126v is covered by an approximately steel plate 152b secured to perimeter joist 126v with welds 154a and 154b. Perimeter joists 126u and 126v are secured to each other with welds 154c, 154d, and 154e. Gusset 124n is secured to perimeter joist 126u with welds 154f and 154g and welded to perimeter joist 126v with welds 154h and 154i. Gusset 142n may be located approximately 5 from the bottom edges of perimeter joists 126u and 126v.

[0026] FIGS. 7C, 7D, and 7E, which provide elevation views of cross sections, illustrate example pour stops 146g, 146h, and 146i. Pour stop 146g may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is approximately 1 inside the exterior edge of perimeter joist 126w. Pour stop 146g may be secured to perimeter joist 126w with weld 154h. As described above, the placement of pour stop 146g on perimeter joist 126w (together with the placement of another pour stop 146 on another perimeter joist 126) may create a leaveout 150 between floors 108 mated to each other. Pour stop 146g may be used for a poured threshold along a mateline between floors 108. Pour stop 146h may be a minimum 20-gauge pour stop with a return lip, placed such that its exterior edge is approximately outside the exterior edge of perimeter joist 126x. In particular embodiments, a perimeter joist 126 that has a pour stop 146 arranged as shown in FIG. 7C may be mated with a perimeter joist 126 that has a pour stop 146 arranged as shown in FIG. 7D. Pour stop 146h may be secured to perimeter joist 126x with weld 154k. Pour stop 146h may be used for a flush threshold along a mateline between floors 108. Pour stop 146i may be a minimum 20-gauge pour stop with a return lip, placed such that it extends a minimum of 2 over the top flange of perimeter joist 126y. Pour stop 146h may be secured to perimeter joist 126y and pan 124i with welds 154l and 154m, respectively.

[0027] FIG. 7F, which provides an elevation view of a cross section, illustrates an example side-lap joint 156 between example pans 124j and 124k. Pans 124j and 124k may constitute all or a portion of a single pan 124. A pan 124 may include one or more pans 124, and reference herein to a pan 124 may include multiple pans 124, and vice versa, where appropriate. In the example of FIG. 7F, pans 124j and 124k overlap at side-lap joint 156, with pan 124k being laid on top of pan 124j. Pans 124j and 124k may be attached to each other using one or more screws 158a (which may be #10 self-tapping screws), one or more crimp or button punches, or one or more minimum puddle or 1 long fillet welds, where appropriate. Although particular joints between particular pans with particular attachments are described and illustrated herein, this disclosure contemplates any suitable joints between any suitable pans with any suitable attachments. These attachments may be place along side-lap joint 156 at a maximum of approximately every 36. Concrete 122i is set in pans 124j and 124k and reinforced with a wire mesh 144g (which may be a 66-W1.4W1.4 wire mesh welded in places to pans 124j and 124k or set on top of plastic or other bar chairs or risers on pans 124j and 124k).

[0028] FIG. 7G, which provides an elevation view of a cross section, illustrates an example butt joint 160 between example pans 124l and 124m. Pans 124l and 124m may constitute all or a portion of a single pan 124. Concrete 122j is set in pans 124l and 124m and reinforced with a wire mesh 144h, which may be a 66-W1.4W1.4 wire mesh set on top of plastic or other bar chairs or risers on pans 124l and 124m. FIG. 7G shows a C8 or strut with pans 124l and 124m sitting on top of and fastened to the C8, with concrete 122j being poured on top of deck (with wire mesh suspended with chairs). Pans 124l and 124m are lapped approximately 2 at butt joint 160 over cross member 134x and secured to each other and cross member 134x with a weld 154l (which may be an approximately arc spot weld). Pans 124l and 124m may also be secured separately to other cross members 134 with other welds, e.g., at approximate spacings of 12.

[0029] FIG. 7H illustrates example cross-sectional dimensions of an example cross member 134y. Cross member 134y may be American Society for Testing and Materials (ASTM) A992 steel or another suitable material.

[0030] FIG. 7I, which provides an elevation view of a cross section, illustrates an example floor-support section. In the example of FIG. 7I, wall 106e includes typical wall framing and insulation with gypsum board on the interior and wall sheathing on the exterior. Wall 106e also includes a 26 treated bottom plate 128e, which is secured to a bottom plate 132e of floor 108i. As indicated by reference number 130c, the wall sheathing of wall 106e extends down to approximately 1 from the bottom of a perimeter joist 126z of floor 108i. The wall sheathing of wall 106e is secured to perimeter joist 126z with screws 158c, which may include two rows of self-tapping screws at approximately every 4 along the length of perimeter joist 126z. Floor 108i includes concrete 122k set in a pan 124n and reinforced with a wire mesh 144i (which may be a 66-W1.4W1.4 wire mesh welded in places to pan 124n or set on top of plastic or other bar chairs or risers on pan 124n). Concrete 122k may be lightweight concrete and have a total slab depth of approximately 4. Pan 124n may be a 22-gauge minimum 2 composite metal deck. Pan 124n may be supported by a cross member 134y (and by other cross members 134 not shown in FIG. 7I). Pan 124n may be secured to cross member 134y (and to other cross members 134 that are not shown in FIG. 7I) with welds 154o and 154p (and with other welds 154 that are not shown in FIG. 7I). Those welds 154 between pan 124n and cross member 134y may be approximately arc spot welds at approximately every 12 along the length of cross member 134y. Floor 108i also includes perimeter joist 126z, a 24 treated bottom plate 132e, cross member 134y, and a metal plate 136c. Perimeter joist 126z has an interior-facing channel. Bottom plate 132e is secured to perimeter joist 126z with screws 158b (which may be #8 minimum self-tapping screws) at approximately every 12 along the length of perimeter joist 126z. Cross member 134y may be made of steel. Plate 136c may be a 46 plate and used to fasten perimeter joist 126z to cross member 134y. Plate 136c is fastened to perimeter joist 126z with a weld 154m along an edge of plate 136c abutting perimeter joist 126z. Plate 136c is fastened to cross member 134y with a weld 154n along the other three edges of plate 136c. Another plate 136, similar to and positioned similarly to plate 136c, on the other side of cross member 134y may also be used to fasten perimeter joist 126a to cross member 134y and may be similarly fastened to perimeter joist 126z and cross member 134y.

[0031] FIG. 7J, which provides an elevation view of a cross section, illustrates an example perimeter-channel brace section. In the example of FIG. 7J, wall 106f includes typical wall framing and insulation with gypsum board on the interior and wall sheathing on the exterior. Wall 106f also includes a 26 treated bottom plate 128f, which is secured to a bottom plate 132f of floor 108j. As indicated by reference number 130d, the wall sheathing of wall 106f extends down to approximately 1 from the bottom of a perimeter joist 126aa of floor 108j. The wall sheathing of wall 106f is secured to perimeter joist 126aa with screws 158e, which may include two rows of self-tapping screws at approximately every 4 along the length of perimeter joist 126aa. Floor 108j includes concrete 122l set in a pan 124o and reinforced with a wire mesh 144j (which may be a 66-W1.4W1.4 wire mesh welded in places to pan 124o or set on top of plastic or other bar chairs or risers on pan 124o). Pan 124o is butted up to perimeter joist 126aa. Pan 124o may be a composite deck supported by one or more cross members 134 of floor 108j (which are not shown in FIG. 7J). Floor 108j also includes perimeter joist 126aa, a 24 treated bottom plate 132f, a brace member 140f, and metal plates 136d and 136e. Perimeter joist 126aa has an interior-facing channel. Bottom plate 132f is secured to perimeter joist 126aa with screws 158d (which may be #8 minimum self-tapping screws) at approximately every 12 along the length of perimeter joist 126aa. Brace member 140f may be made of steel. There may be a void space 160 between brace member 140f and pan 124o. Plate 136d may be a 44 plate and used to secure perimeter joist 126aa to brace member 140f. Plate 136d is secured to perimeter joist 126aa with a weld 154r along an edge of plate 136d abutting perimeter joist 126aa. Plate 136d is secured to brace member 140f with a weld 154s along the other three edges of plate 136d. Another plate 136, similar to and positioned similarly to plate 136d, on the other side of brace member 140f may also be used to secure perimeter joist 126aa to brace member 140f and may be similarly secured to perimeter joist 126aa and brace member 140f. Plate 136e may also be a 44 plate and used to secure perimeter joist 126aa to brace member 140f. Plate 136e is secured to perimeter joist 126aa with a weld 154q (which may be a fillet weld) along an edge of plate 136e abutting perimeter joist 126aa. Plate 136e is secured to brace member 140f with another weld along the other three edges of plate 136e. Another plate 136, similar to and positioned similarly to plate 136e, on the other side of brace member 140f may also be used to secure perimeter joist 126aa to brace member 140f and may be similarly secured to perimeter joist 126aa and brace member 140f.

[0032] FIG. 7K, which provides an elevation view of a cross section, illustrates an example end support. In the example of FIG. 7K, wall 106g includes typical wall framing and insulation with gypsum board on the interior and wall sheathing on the exterior. Wall 106g also includes a 26 treated bottom plate 128g, which is secured to a bottom plate 132g of floor 108k. As indicated by reference number 130e, the wall sheathing of wall 106g extends down to approximately 1 from the bottom of a perimeter joist 126ab of floor 108k. The wall sheathing of wall 106g is secured to perimeter joist 126ab with screws 158g, which may include two rows of self-tapping screws at approximately every 4 along the length of perimeter joist 126ab. Floor 108k includes concrete 122m set in a pan 124p and reinforced with a wire mesh 144k (which may be a 66-W1.4W1.4 wire mesh welded in places to pan 124p or set on top of plastic or other bar chairs or risers on pan 124p). Floor 108k also includes perimeter joist 126ab and a 24 treated bottom plate 132g. Perimeter joist 126ab has an exterior-facing channel covered by a steel plate 152c welded in place. Bottom plate 132g is secured to perimeter joist 126ab with screws 158g (which may be #8 minimum self-tapping screws) at approximately every 12 along the length of perimeter joist 126ab. Pan 124p may be a composite deck supported by one or more cross members 134 of floor 108k (which are not shown in FIG. 7K). In FIG. 7K, pan 124p sits on top of and is fastened to bracket (or angle iron) 162. Pan 124p is also supported by a bracket 162 secured to perimeter joist 126ab and pan 124p. Bracket 162 may be a 44 L bracket. Bracket 162 is secured to perimeter joist 126ab with welds 154u and 154v. Bracket 162 is secured to pan 124p with a weld 154w, which may be an approximately arc spot weld.

[0033] FIG. 8 illustrates an example method 800 for constructing a modular or pre-fabricated home. The home may be constructed along an assembly line with stations where particular construction activities or tasks are performed. The assembly line may include an air caster system for moving the home along the assembly line as construction progresses. There may be one or more offsets from the assembly line that each include one or more stations apart from the assembly line where one or more components or systems of the home may be constructed independent of activities or tasks being performed along the assembly line. Those components or systems may then be transferred to the assembly line, where they may be built on or added to or integrated with one or more other components or systems of the home. In particular embodiments, the offset reduces bottlenecks in the assembly line and increases its throughput. In particular embodiments, in addition or as an alternative, the offset facilitates separation of welding equipment from lumber or other flammable materials, which improves safety and reduces liability in the operation of the assembly line.

[0034] Method 800 begins at step 802, where, at an offset from the assembly line, the steel frame of a floor 108 (e.g. including perimeter joists 126, cross members 134, brace members 140, gussets 142, and pan 124) is constructed at a first station. Activities at the first station may include structural framing, composite decking, reinforcements, and screeds. Step 802 may include one or more of the following, in any suitable order: [0035] Cutting structural steel members cut to length, cutting or drilling holes, and removing loose rust from steel surfaces; [0036] Receiving and documenting structural beam components; [0037] Assembling the frame of floor 108 in a framing jig; [0038] Installing pan 124; [0039] Removing floor 108 rom the framing jig and placing floor 108 in a concrete-pour area; [0040] Installing a wire mesh 144 in floor 108 at a correct height above pan 124; or [0041] Installing perimeter screeds.

[0042] At step 804, floor 108 is transferred to the assembly line. At step 806, at one or more stations of the assembly line, concrete 122 is poured into pans 12. Activities at these stations may include pouring concrete 122 into pan 124, troweling concrete 122 to a smooth finish, and marking the perimeter of floor 108 with a serial number and module unit designation. At step 808, at one or more stations of the assembly line, wood framing and rough mechanical, electrical, and plumbing (MEP) features are constructed or installed. Activities at these stations may include wall and partition assembly, rough mechanical, rough electrical, and rough plumbing. At step 810, at one or more stations of the assembly line, drywall, insulation, and tile are constructed or installed. This may include constructing or installing an interior finish (e.g. drywall, spackling, primer, and paint), insulation, and tile. At step 812, at one or more stations of the assembly line, sheathing and millwork are constructed or installed. Activities at these stations may include installation of exterior sheathing, installation of exterior tape, and construction or installation of cabinets, countertops, and trim.

[0043] At step 814, at one or more stations of the assembly line, MEP is finished. Activities at these stations may include finishing and testing mechanical, electrical, or plumbing components or systems of the home. At step 816, at one or more stations of the assembly line, doors and windows are constructed or installed and punching and wrapping is performed, at which point the method ends. Activities at these stations may include constructing or installing exterior windows and doors, punching, decaling, cleaning, and wrapping. Activities at these stations may include constructing or installing exterior windows, doors assemblies, interior-accessory finishes, and accessories. Activities at these stations may also include a final punch inspection, installation of state decals and data plates, cleaning of the home, wrapping the home, and preparing the home for shipping.

[0044] On the assembly line, activities or operations with respect to walls and partitions may include one or more of the following, in any suitable order and at any suitable stations: [0045] Cutting wall plates required lengths; [0046] Laying out wall plates with window and door openings located; [0047] Placing door and window subassemblies in required locations; [0048] Assembling studs and wall plates in wall-framing jig; [0049] Nailing studs plates; [0050] Squaring off wall prior to sheathing; [0051] Applying gypsum board and fastening it to studs and plates; [0052] Removing completed subassembly and placing it in stand for next operation; [0053] Placing wall assemblies on floor assembly and arranging them according to floorplan; [0054] Securing partition walls to floor assembly and at wall intersections; [0055] Securing exterior walls to floor 108 and partitions; or [0056] Installing blocking for fastening of walls, bath accessories, shelving, and fixtures.

[0057] On the assembly line, activities or operations with respect to ceilings and roofs may include one or more of the following, in any suitable order and at any suitable stations: [0058] Pre-assembling roof trusses; [0059] Applying gypsum board to ceiling or roof frame; [0060] Placing beams in required locations; [0061] Assembling ceiling or roof frame in framing jig; [0062] Framing rough openings for stairs chases, skylights, and attic accesses; [0063] Installing blocking for fastening of walls to ceiling or roof frame; [0064] Fastening gypsum board to framing members; [0065] Installing lateral bracing for trusses (rat runs); or [0066] Placing completed roof/ceiling assembly on and attaching it to module walls.

[0067] On the assembly line, activities or operations with respect to rough plumbing may include one or more of the following, in any suitable order and at any suitable stations: [0068] Installing rough-in water supply lines; [0069] Installing rough-in drain, waste, and vent lines; [0070] Installing rough-in hydronic-heat lines; [0071] Installing rough-in gas-supply lines; [0072] Installing rough-in fire-suppression lines; [0073] Installing rough-in central-vacuum lines; [0074] Installing rough-in condensation-drain lines; [0075] Installing support blocking for plumbing lines; [0076] Securing plumbing lines; [0077] Installing pipe insulation; [0078] Installing tub or shower units and completing drain connections; [0079] Installing draft stops at plumbing operations of fire-rated assemblies; [0080] Extending main vent through roof; or [0081] Testing plumbing lines during each installation phase prior to concealment.

[0082] On the assembly line, activities or operations with respect to rough electrical may include one or more of the following, in any suitable order and at any suitable stations: [0083] Cutting holes in gypsum board and installing electrical device boxes; [0084] Installing main panel box, sub-panel box, and main breaker; [0085] Installing electrical junction boxes; [0086] Installing electrical conduit; [0087] Installing main power and ground wires; [0088] Installing branch circuit wiring; [0089] Installing coaxial cable; [0090] Installing telephone, thermostat, and bell wiring; [0091] Installing wire protectors and securing wiring; [0092] Installing draft-stopping caulk; [0093] Installing fire-stopping caulk; or [0094] Installing mechanical ventilation fans.

[0095] On the assembly line, activities or operations with respect to heating, ventilation, and air conditioning (HVAC) may include one or more of the following, in any suitable order and at any suitable stations: [0096] Installing HVAC register boots, wall stacks, and ductwork; [0097] Installing metal HVAC ductwork; [0098] Installing smoke and fire dampers in ducts at fire-rated assembly penetrations; [0099] Installing draft-stopping caulk; [0100] Installing fire-stopping caulk; [0101] Installing furnace or in-air handler; or [0102] Installing plenum.

[0103] On the assembly line, activities or operations with respect to insulation or sheathing may include one or more of the following, in any suitable order and at any suitable stations: [0104] Installing thermal insulation in exterior wall assemblies; [0105] Installing thermal insulation in roof/ceiling assembly; [0106] Installing exterior rated sheathing on exterior wall assemblies and cutouts at rough openings; [0107] Installing exterior rated sheathing on roof assembly and cutouts at rough openings; or [0108] Installing air-filtration barrier on exterior wall.

[0109] On the assembly line, activities or operations with respect to interior finish may include one or more of the following, in any suitable order and at any suitable stations: [0110] Installing sound attenuation insulation in partition assemblies; [0111] Installing remaining gypsum board on partition assemblies; [0112] Installing soffits; [0113] Tapping gypsum-board seams and corners and applying joint compound; [0114] Installing metal corner beads on outside corners; [0115] Spraying smooth texture coat on surfaces; [0116] Painting walls, partitions, and ceiling surfaces; [0117] Installing ceramic and slate tiles; [0118] Installing base, wall, and vanity cabinets; [0119] Installing countertops, lavatory tops, and backsplashes; [0120] Installing medicine cabinets and mirrors; [0121] Installing shelving; [0122] Installing interior door jambs, hinges, and doors; [0123] Installing interior door lock and passage sets; or [0124] Installing vase, casing, and cove moldings.

[0125] On the assembly line, activities or operations with respect to doors and windows may include one or more of the following, in any suitable order and at any suitable stations: [0126] Installing flashing around window and door rough opening; [0127] Installing and caulking windows; [0128] Installing and caulking exterior entry and patio doors; [0129] Installing exterior door hardware, including locksets, deadbolts, and peep sights;

[0130] On the assembly line, activities or operations with respect to exterior finishes may include one or more of the following, in any suitable order and at any suitable stations: [0131] Installing roof flashing, penetration boots, and pitch pockets; [0132] Installing roof drains or overflow boxes; [0133] Installing roofing underlayment; [0134] Installing drip edge; [0135] Installing finish roofing; [0136] Installing vent caps; [0137] Installing roof eave fascia, soffit panels, and trim accessories; [0138] Installing and caulking flashings at window and exterior door heads; [0139] Installing exterior wall felt or infiltration barrier; [0140] Installing exterior wall finish, trim, and accessories; [0141] Applying caulking; or [0142] Commencing transport weather protection.

[0143] On the assembly line, activities or operations with respect to finishing electrical may include one or more of the following, in any suitable order and at any suitable stations: [0144] Installing and wiring devices; [0145] Installing device cover plates; [0146] Installing branch circuit breakers; [0147] Wiring panel; [0148] Testing electrical system; [0149] Installing light fixtures; [0150] Installing exhaust fans and range hoods; [0151] Installing smoke, carbon monoxide, and heat detectors; [0152] Installing fire and life safety signaling devices; [0153] Labeling wires terminating in junction boxes for modular-unit crossover connection at home site; or [0154] Installing furnace or air handler.

[0155] On the assembly line, activities or operations with respect to finishing plumbing may include one or more of the following, in any suitable order and at any suitable stations: [0156] Installing water heater and connecting it to water-supply system; [0157] Installing sinks and lavatories and connecting them to drain, waste, and vent system; [0158] Installing kitchen-sink disposal; [0159] Installing faucets and connecting them to water-supply system; [0160] Installing toilets and connecting them to water-supply system and drain, waste, and vent system; [0161] Completing under-floor plumbing; or [0162] Labeling plumbing lines terminating for modular-unit crossover connection at home site.

[0163] On the assembly line, activities or operations with respect to final finishes may include one or more of the following, in any suitable order and at any suitable stations: [0164] Installing filler in fastener holes in moldings; [0165] Installing doorstops; [0166] Installing bath and powder-room accessories; [0167] Installing shower-curtain rod or shower doors; [0168] Installing HVAC registers and grills; [0169] Performing cosmetic repairs on interior finishes; [0170] Removing debris modular unit; [0171] Cleaning modular unit; [0172] Loading and securing for shipment home-site-completion materials (ship loose); [0173] Attaching third-party-inspection-agency and state-approval labels to approved location inside modular unit; [0174] Attaching modular data plate adjacent to labels; [0175] Closing and weatherproofing modular unit and preparing it for shipment; [0176] Marking outside of modular unit serial number, modular-unit designation, and other designations; or [0177] Loading modular unit onto transport frame, securing modular unit for shipment, and moving modular unit and transport frame to storage yard to await shipment.

[0178] Particular embodiments may repeat one or more steps of method 800, where appropriate. Although this disclosure describes and illustrates particular steps of method 800 as occurring in a particular order, this disclosure contemplates any suitable steps of method 800 occurring in any suitable order. Moreover, although this disclosure describes and illustrates an example method for constructing an example floor for a modular or pre-fabricated home including the particular steps of method 800, this disclosure contemplates any suitable method for constructing an example floor for a modular or pre-fabricated home including any suitable steps, which may include all, some, or none of the steps of method 800, where appropriate.

[0179] FIG. 9 illustrates an example method 900 for installing a modular or pre-fabricated home at a home site. Before method 900 begins, one or more portions 100 of the home including one or more floors 108 may be constructed in whole or in part at a factory and then transported to the home site by a vehicle, as described above. In addition, a foundation 110 may be constructed for the home at the home site. Foundation 110 may include helical piers set on foundation footings in the ground. The piers may include metal embed plates 138. Water, electric, natural gas, propane, sewer, septic, or other connections may also be prepared for the home at the home site.

[0180] Method 900 begins at step 902, where a portion 100 of the home that includes a floor 108 is moved at the home site from the vehicle it was transported on to foundation 110. This may include portion 100 being lifted off the vehicle and laterally set on foundation 110 by a forklift, side loader, or other suitable equipment. At step 904, portion 100 is leveled on foundation 110 as appropriate. This may include shimming portion 100 on foundation 110 or leveling portion 100 on foundation 110 in another suitable manner. At step 906, portion 100 is secured to foundation 110 by, for example, welding floor 108 of portion 100 to metal embed plates 318 on the piers of foundation 110. For example, one or more perimeter joists 126, cross members 134, or brace members 140 of floor 108 may be welded in one or more locations to metal embed plates 318 on the piers of foundation 110. In particular embodiments, steps 902, 904, and 906 may be repeated for one or more other portions 100 of the home that were transported to the home site. At step 908, the rest of the home is completed at the home site, at which point the method ends. Completion of the rest of the home at step 908 may include mating different floors 108 of the home to each other; finishing a roof 102 or one or more other components or systems of the home; tying the home to the prepared water, electric, natural gas, propane, sewer, septic, or other connections; applying exterior finishes and final touches to the home; or performing other suitable tasks. In particular embodiments, method 900 may reduce costs or time requirements associated with installing the home at the home site; reduce the pouring or setting of concrete at the home site; facilitate the focus of warranties and repairs on the foundation of the home to steel, welds, and piers, which may be beneficial to the builder; or provide one or more other advantages.

[0181] Particular embodiments may repeat one or more steps of method 900, where appropriate. Although this disclosure describes and illustrates particular steps of method 900 as occurring in a particular order, this disclosure contemplates any suitable steps of method 900 occurring in any suitable order. Moreover, although this disclosure describes and illustrates an example method for installing a modular or pre-fabricated home including the particular steps of method 900, this disclosure contemplates any suitable method for installing a modular or pre-fabricated home including any suitable steps, which may include all, some, or none of the steps of method 900, where appropriate.

[0182] Herein, or is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, A or B means A, B, or both, unless expressly indicated otherwise or indicated otherwise by context. Moreover, and is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, A and B means A and B, jointly or severally, unless expressly indicated otherwise or indicated otherwise by context.

[0183] The scope of this disclosure includes all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. The embodiments disclosed herein are only examples, and the scope of this disclosure is not limited to them. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Particular embodiments may include all, some, or none of the components, elements, features, functions, operations, or steps of the embodiments disclosed herein. Furthermore, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments may provide none, some, or all of these advantages.