Abstract
A wooden module for use in constructing a building including a wooden ceiling assembly. A plurality of wooden side wall assemblies are configured for attachment to opposite sides of the wooden ceiling assembly. A wooden floor assembly is configured for attachment to the wooden side wall assemblies. The wooden side wall assemblies extend to a top of the wooden ceiling assembly and to a bottom of the wooden floor assembly such that the wooden ceiling assembly and the wooden floor assembly contact inner sides of the wooden side wall assemblies when the wooden ceiling assembly and wooden floor assembly are attached to the wooden side wall assemblies.
Claims
1. A wooden module connectable with one or more additional wooden modules to construct a building, the module comprising: a wooden ceiling assembly; a plurality of wooden side wall assemblies configured for attachment to opposite sides of the wooden ceiling assembly; and a wooden floor assembly configured for attachment to the wooden side wall assemblies, the wooden side wall assemblies extending to a top of the wooden ceiling assembly and to a bottom of the wooden floor assembly such that the wooden ceiling assembly and the wooden floor assembly contact inner sides of the wooden side wall assemblies when the wooden ceiling assembly and wooden floor assembly are attached to the wooden side wall assemblies.
2. The module of claim 1, further comprising a wooden end wall assembly configured for attachment to ends of the wooden ceiling assembly, wooden side wall assemblies, and wooden floor assembly.
3. The module of claim 1, wherein the wooden side wall assemblies each include a top plate assembly, a bottom plate assembly, and a plurality of studs extending between the top and bottom plate assemblies.
4. The module of claim 3, wherein the plurality of studs comprises first studs extending between the top and bottom plate assemblies, and at least one second stud extending between the top and bottom plate assemblies, the first studs each having a length that is longer than the at least one second stud.
5. The module of claim 4, wherein the first studs each include a bottom portion extending past a bottom of the top plate assembly and a top portion extending past a top of the bottom plate assembly, and the at least one second stud extends to the bottom of the top plate assembly and to the top of the bottom plate assembly.
6. The module of claim 4, wherein the at least one second stud is disposed at an end of the side wall assembly.
7. The module of claim 3, wherein the bottom plate assembly comprises a first bottom plate and a header mounted directly on top of the first bottom plate.
8. The module of claim 7, wherein the first studs extend past the header to the bottom plate.
9. The module of claim 8, wherein the first studs have a notch formed therein configuring end portions of the first studs to extend around the header to the bottom plate.
10. The module of claim 9 wherein the end portion attached to the header at two locations spaced apart along the length of the first stud.
11. The module of claim 7, wherein the top plate assembly comprises a top plate and a header mounted directly on a bottom of the top plate.
12. The module of claim 11, further comprising fasteners extending through the headers to attach the wooden side wall assemblies to the wooden ceiling assembly and wooden floor assembly.
13. The module of claim 7, wherein the bottom plate assembly comprise a second bottom plate disposed directly on top of the header, the at least one second stud being disposed on top of the second bottom plate.
14. The module of claim 13, wherein a recess is formed between the first bottom plate, one of the first studs, and the second bottom plate.
15. The module of claim 14, further comprising a splice plate disposable in the recess for attaching the module to another one of the modules.
16. A wall assembly for use in a module for constructing a building, the wall assembly comprising: a top plate assembly including a top plate and a header mounted directly on a bottom of the top plate; a bottom plate assembly comprises a bottom plate and a header mounted directly on top of the bottom plate; and a plurality of studs extending between the top and bottom plate assemblies, the plurality of studs comprising first studs extending between the top and bottom plate assemblies, and at least one second stud extending between the top and bottom plate assemblies, the first studs each having a length that is longer than a length of the at least one second stud.
17. The assembly of claim 16, wherein the top plate, bottom plate, and headers extend continuously along an entire length of the wall assembly.
18. The assembly of claim 16, wherein the first studs extend past a bottom of the top plate assembly and past a top of the bottom plate assembly, and the at least one second stud extends to the bottom of the top plate assembly and to the top of the bottom plate assembly.
19. The assembly of claim 16, wherein the at least one second stud is disposed at an end of the side wall assembly.
20. The assembly of claim 16, wherein the first studs extend past the header on the top plate to the top plate at the top plate assembly, and extend past the header to the bottom plate to the bottom plate at the bottom plate assembly.
21. The assembly of claim 20, wherein the first studs have first notches formed therein configuring bottom portions of the first studs to extend around the header on the bottom plate, and second notches formed therein configuring top portions of the first studs to extend around the header on the top plate.
22. A ceiling assembly for use in a module for constructing a building, the ceiling assembly comprising: a first ceiling plate extending; a second ceiling plate extending; a plurality of ceiling joists extending between the first and second ceiling plates, each ceiling joist comprising a truss assembly including a plurality of truss members; and a support block attached to at least one of the truss members, the support block providing a support surface for supporting MEP (mechanical, electrical, and plumbing) components extending through the ceiling joists.
23. The assembly of claim 22, further comprising indicia on the support block for instructing how to extend the MEP components through the ceiling joists.
24. The assembly of claim 23, wherein the indicia provides information regarding the direction and pitch to extend the MEP components.
25. The assembly of claim 23, wherein the indicia comprises at least one of colored markings, arrows, or writing.
26. The assembly of claim 22, further comprising the MEP components pre-installed on the ceiling assembly prior to attachment of the ceiling assembly in the module.
27. The assembly of claim 22 wherein the support block is positioned at the desired location of the MEP component prior to installation of the MEP component.
28. A wooden module assembly comprising: a first wooden module including a first wooden ceiling assembly, a plurality of first wooden side wall assemblies configured for attachment to opposite sides of the first wooden ceiling assembly, and a first wooden floor assembly configured for attachment to the first wooden wall assemblies; and a second wooden module including a second wooden ceiling assembly, a plurality of second wooden side wall assemblies configured for attachment to opposite sides of the second wooden ceiling assembly, and a second wooden floor assembly configured for attachment to the second wooden wall assemblies, the first wooden module being attached to the second wooden module at the first and second wooden side wall assemblies.
29. The assembly of claim 27, further comprising a splice place connecting the first wooden module to the second wooden module.
30. The assembly of claim 27, further comprising a third wooden module attached to the second wooden module.
31. The assembly of claim 29, wherein the third wooden module comprises a wooden floor assembly and a wooden ceiling assembly, the third wooden module being free of wall assemblies.
32. The assembly of claim 27, wherein the first wooden module comprises a dry module such that the first wooden module is free of plumbing ducts, and the second wooden module comprise a wet module such that the second wooden module includes plumbing components.
Description
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective of a module assembly of the present disclosure;
[0008] FIG. 2A is a schematic perspective view of the module assembly;
[0009] FIG. 2B is a schematic perspective view of the module assembly with ceiling assemblies removed to show internal structure;
[0010] FIG. 3 is a fragmentary perspective view of the module assembly of FIG. 1 with end wall assemblies removed;
[0011] FIG. 4 is a fragmentary, perspective view of a floor assembly and side wall assembly of a first module of the module assembly of FIG. 1;
[0012] FIG. 5 is an illustration of assemblies of the first module stacked on top of each other for transport;
[0013] FIG. 6 is an enlarged, fragmentary perspective view of a side wall assembly of the first module;
[0014] FIG. 7 is an illustration of a fragmentary portion of a side wall assembly of the first module;
[0015] FIG. 8 is an enlarged fragmentary right side view of the first module;
[0016] FIG. 9 is an end view of the first module showing an end wall assembly and with a ceiling assembly removed;
[0017] FIG. 10 is an enlarged, fragmentary end view of the first module;
[0018] FIG. 11 is an end view of the first module with a floor assembly and end wall assembly removed;
[0019] FIG. 12A is a fragmentary left perspective view of the first module of FIG. 9;
[0020] FIG. 12B is a fragmentary left side view of the first module;
[0021] FIG. 12C is an enlarged, fragmentary left side view of the first module;
[0022] FIG. 13A is an enlarged, fragmentary left side view of the first module;
[0023] FIG. 13B is an enlarged, fragmentary left perspective view of the first module;
[0024] FIG. 14A is a fragmentary end view of the first module with the floor assembly removed;
[0025] FIG. 14B is an enlarged, fragmentary end view of the first module of FIG. 14A
[0026] FIG. 15 is a right perspective view of a side wall assembly and floor assembly of a second module of the module assembly;
[0027] FIG. 16 is an enlarged, fragmentary right side view of the second module of FIG. 15;
[0028] FIG. 17 is the end view of the second module with a ceiling assembly removed;
[0029] FIG. 18 is an enlarged fragmentary end view of the second module of FIG. 17;
[0030] FIG. 19 is a perspective view of the ceiling assembly of the second module;
[0031] FIG. 20 is an enlarged fragmentary perspective view of the ceiling assembly of the second module;
[0032] FIG. 21 is an enlarged fragmentary perspective view of the ceiling assembly of the second module showing MEP components mounted in the ceiling assembly;
[0033] FIG. 22 is a right perspective view of the second module with the ceiling assembly removed;
[0034] FIG. 23A is a right side, fragmentary view of the second module of FIG. 22;
[0035] FIG. 23B is an enlarged, fragmentary view of the second module of FIG. 23A;
[0036] FIG. 24 is a right perspective view of the second module with a floor assembly removed;
[0037] FIG. 25A is a fragmentary right perspective view of a side wall assembly and ceiling assembly of the second module;
[0038] FIG. 25B is a fragmentary left perspective view of a side wall assembly and ceiling assembly of the second module;
[0039] FIG. 26 is a perspective view of the second module with the floor assembly removed;
[0040] FIG. 27 is a left perspective view of second module with a floor assembly of a third module attached to the second module;
[0041] FIG. 28A is an enlarged, fragmentary perspective view of the modules of FIG. 27;
[0042] FIG. 28B is an enlarged, fragmentary perspective view of the modules of FIG. 27;
[0043] FIG. 29 is a left perspective view of second and third modules;
[0044] FIG. 30A is an end view of the second and third modules;
[0045] FIG. 30B is an enlarged fragmentary perspective view of the modules of Fig. 30A;
[0046] FIG. 31A is an enlarged fragmentary perspective view showing a connection between the first and second modules;
[0047] FIG. 31B is an enlarged fragmentary side view showing the connection between the first and second modules at bottom plate assemblies of the modules;
[0048] FIG. 31C is an enlarged fragmentary side view showing the connection between the first and second modules at top plate assemblies of the modules;
[0049] FIG. 32 is an exploded view of a pair of module assemblies attachable together
[0050] FIG. 33 is an enlarged fragmentary perspective of the module assembly showing a drain pipe installed in a wall assembly.
[0051] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION
[0052] Referring to FIGS. 1 and 2, a module assembly of the present disclosure is generally indicated at 11. The module assembly 11 may comprise a modular component of a building framework such that the building framework may consist at least primarily of multiple interconnected module assemblies. Each module assembly 11 may comprise a plurality of modules 12, 14, 16 that can be attached together to form the module assembly. Each module 12, 14, 16, or module assembly 11, used in the construction of a building framework may also be referred to as a skeleton, frame, wooden cage, or cage. For example, multiple assembled module assemblies 11 may be disposed end-to-end, side-by-side, and/or stacked on top of each other to form the framework of a building. In the illustrated embodiment, each module 12, 14, 16 of the module assembly 11 comprises a wooden module such that an entirety of the structural framework of the module is formed from wood. For example, the module assembly 11 may be formed from engineered lumber (structural composite lumber). However, the modules 12, 14, 16 could be at least partially or entirely formed from another material, such as steel, without departing from the scope of the disclosure. In one embodiment, the assembly 11 comprises a first dry module 12, a second wet module 14, and a third corridor module 16. For example, the first module 12 may comprise the framework for a bedroom, the second module 14 may comprise the framework for a bathroom, and the third module 16 may comprise the framework for a hallway. As such, the first, second, and third modules 12, 14, 16 may be attached to form the framework of a single hotel or apartment room within a building. It will be understood that other room types may be configured with the module assembly 11 without departing from the scope of the disclosure.
[0053] Referring to FIGS. 1, 3, and 4, the first module 12 comprises a pair of side wall assemblies 15, a ceiling assembly 13 attachable to tops of the side wall assemblies, a floor assembly 17 attachable to bottoms of the side wall assemblies, and an end wall assembly 19 attachable to ends of the side wall assemblies, floor assembly, and ceiling assembly. The side wall assemblies 15, and end wall assembly 19 to a lesser extent, are configured to support the floor assembly 17 and ceiling assembly 13 such that floor assembly and ceiling assembly may be hung from sides of the side wall assemblies. Thus, the first module 12 can be suitably erected by separately attaching the wall assemblies 15, 19 to the floor assembly 17 and then attaching the ceiling assembly to the wall assemblies. In this respect, the floor assembly 17 and ceiling assembly 13 may be hung from the wall assemblies 15, 19 such that the weight of the floor and ceiling assemblies are supported by the wall assemblies. Other orders of attachment of the assemblies 13, 15, 17, 19 are also envisioned without departing from the scope of the disclosure. In one embodiment, the first module 12 incorporates balloon framing in the construction of the module.
[0054] Thus, the bottoms of the side wall assemblies 15 extend below or at least to bottoms of the floor assembly 17. The side wall assemblies 15, 19 each form a deep beam that can support the load of the module 12 when lifted. The wall assemblies 15, 19 are sufficiently strong to prevent substantial downward deflection or bowing when the module 12 is picked up by the side wall assemblies. Therefore, it is not necessary to pick up by supporting the floor assembly 17 from underneath. The wall assemblies 15, 19 can bear the weight of the floor assembly 17, so that the module 12 can be picked up from above for positioning a stacking in a modular building construction. This is different from other construction framing where the floor provides the support for the walls, and thus the floor extends below the walls. As a result, the module 12 can be handled (e.g., lifted) by direct engagement with the side wall assemblies 15 when the module is moved during erection of a building. Additionally, the balloon framing separates the floor assemblies of adjacent modules 12, 14, 16 thereby isolating vibrations (i.e., noise) at each floor assembly preventing the vibrations from traveling from one module to the next. This also allows insulation to be provided in the floor assemblies. Still other advantages to the configuration of the modules are envisioned.
[0055] Referring to FIG. 5, the assemblies 13, 15, 17, 19 may be stacked on top of each other for transporting the unassembled modules to a construction site or work site (e.g., an assembly plant) by a single trailer. In one embodiment, the modules 12, 14, 16 are erected and other components are attached to the module to create a completed volumetric module for installation at the construction site. For example, a substantially completed room, including drywall, paint/wall finishing, plumbing, electrical and even furniture could be installed and shipped to a construction site. As used herein, module or wooden module may refer to the modules 12, 14, 16 or to a more fully or completely finished construction unit that includes additional components added to the module cage to partially or fully finish the interior.
[0056] Referring to FIGS. 4 and 6-8, each side wall assembly 15 comprises a top plate assembly or beam assembly 21, a bottom plate assembly or beam assembly 23, a plurality of vertical members or studs 25A, 25B extending between the top and bottom plate assemblies, and a corner post 25C extending between the top and bottom plate assemblies at one end of the side wall assembly. In one embodiment, major surfaces of the studs 25A, 25B extend perpendicular to a length of the side wall assembly 15, and major surfaces of the corner post 25C extend parallel to the length of the side wall assembly. The top and bottom plate assemblies 21, 23 extend parallel to each other, and the studs 25A, 25B and corner post 25C extend parallel to each other. First studs 25A make up the majority of the studs and are spaced inward from the longitudinal ends of the top and bottom plate assemblies 21, 23. The first studs 25A extend into the top and bottom plate assemblies 21, 23 such that the first studs extend past a bottom of the top plate assembly and below a top of the bottom plate assembly. A second stud 25B defines one of the ends of the side wall assembly 15 while the corner post 25C defines the opposite end. The second stud 25B is disposed entirety between the top and bottom plate assemblies 21, 23 such that the second stud extends from a top surface of the bottom plate assembly to a bottom surface of the top plate assembly. As will be explained in greater detail below, this configurations facilities attachment of the first module 12 to the second module 14 at the second stud ends of the wall assemblies 15. The corner post 25C is similar to the first studs 25A in that the corner post extends into the top and bottom plate assemblies 21, 23 such that the corner post extends past a bottom of the top plate assembly and below a top of the bottom plate assembly.
[0057] Panels 26 of plywood or oriented strand board may be attached to the studs 25A-25C (see, FIG. 6). Securing the panels 26 to the studs 25A-25C and other components of the wall assemblies 15 further increases the rigidity of the wall assemblies and allows them to support greater loads. In one embodiment, at least one subpanel 26A of the panels 26 is only temporarily attached to the wall assembly 15. Thus, the subpanel 26A can be removed for access to the interior of the wall assembly 15 after the module 12 has been constructed. The removal can be carried out without damaging the wall assembly. The remaining portions of the panel 26 still provide substantially rigidity for the wall assembly 15.
[0058] The length of the top and bottom plate assemblies 21, 23 may also define a length of the first module 12. A horizontal spacing between the studs 25A, 25B may vary. It will be understood that these dimensions are exemplary only, and that the components of the side wall assemblies 15 may have other dimensions and spacing depending on the desired size and shape of the module 12. In the illustrated embodiment, each of the top and bottom plate assemblies 21, 23, the studs 25A, 25B and the corner post 25C are comprised entirely of rectangular wood members. However, the plate assemblies 21, 23 and studs 25A, 25B, 25C could have other configurations without departing from the scope of the disclosure.
[0059] Referring to FIGS. 4 and 6-8, the bottom plate assembly 23 may comprise a first bottom plate 27 defining a bottom of the side wall assembly 15, a header 29 disposed on top of the bottom plate, and a plurality of spaced apart second bottom plates 31 disposed on the header. In the illustrated embodiment, a single first bottom plate 27 and header 29 extend along the entire length of the side wall assembly 15. The continuous extension of the bottom plate 27 and header 29 provides increased structural rigidity to the side wall assembly 15 at the bottom of the side wall assembly. The second stud 25B seats on top of a second bottom plate 31 disposed on the end of the bottom plate assembly 23. The first studs 25A extend past the second bottom plates 31 and seat on top of the first bottom plate 27 such that the second bottom plates are spaced apart by the first studs. In particular, the first studs 25A include notches 32 at bottom end margins to configure the bottom end margins of the first studs to extend past the header 29 to the first bottom plate 27 and to allow the header 29 to extend continuously across the side wall assembly 15. The notches 32 allow the first studs 25A to engage a major surface of the header 29. Multiple fasteners (e.g., three screws) can be driven through the portion of the first stud 25A overlying the major surface of the header 29 and into the header. The spaced apart relation of the fastener connections of the portion of the first stud 25A overlying the major surface of the header 29 provides a moment couple that strongly resists racking of the studs and can support lateral loads. This construction also permits the module assemblies 11 to transfer lateral loads in a building structure made up of multiple module assemblies. Moreover, the resistance to racking facilitates transportation of the side wall assemblies 15 without damage to the side wall assemblies caused by lateral forces.
[0060] Configuring the first studs 25A and the header 29 in the manner described above also allows for additional plumbing components to be included within the footprint of the wall assembly 15. For instance, a 3-inch (7.6 cm) side deep/thick side wall assembly 15 will be configured to allow plumbing to turn from the side wall to the floor 17 by penetrating the plumbing through the header 29 without compromising the overall structural stability of the module 12. A width or thickness of the first and second bottom plates 27, 31 and first studs 25A is greater than a width/thickness of the header 29 such that the bottom plate assembly 23 defines a plurality of bottom recesses 33 spaced along the length of the side wall assembly 15. Fasteners 36 (FIGS. 31A and 31B) extending through the first and second bottom plates 27, 28 attach the support header 29 to the first and second bottom plates. In one embodiment, the fasteners 36 comprise 3-inch (7.6 cm) screws. Other suitable fasteners may be used.
[0061] Referring to FIG. 33, it may be seen that a mechanical-electrical-plumbing (MEP) component 164 in the form of a drain pipe is shown in the wall assembly 15. The drain pipe 164 extends down from above in the wall assembly 15 to the recess 130. To enter the recess, the second bottom plate 31 is cut to permit the drain pipe 164 to pass into the recess without passing out of the envelope of the wall assembly 15. In the recess 130, the drain pipe 164 makes a turn from vertical to horizontal. The recess 130 provides space to do this without going outside the envelope of the wall assembly 15. After turning, the drain pipe 164 extends generally horizontally (although some variance from horizontal will be maintained to promote gravity flow). An opening is formed in the header 29 that allows the drain pipe 164 to extend through the header and into the floor 17. Preferably, the opening would be formed prior to installation of the drain pipe 164 so that no cutting is required when the drain pipe is installed. Additional supports 166 (broadly, support blocks) (FIG. 1) may be provided for the purpose of supporting an MEP component or an internal fixture such as a sink or a cabinet. The supports 166 not only provide mechanical support for the item, but establish the proper location of that item (e.g., a fixture) in the module 14. The supports 166 may also carry markings so that the proper fixture or other item is attached, as well as providing an indication of where the attachment is to be made. As a result, little or no measurement is required when a fixture is attached to the supports 166.
[0062] Referring to FIGS. 4 and 7, the top plate assembly 21 may comprise a first top plate 37 defining a top of the side wall assembly 15, a second top plate 38 disposed on a bottom of the first top plate, a header 39 disposed on a bottom of the second top plate, and a plurality of third top plates 41 disposed on a bottom of the header. In the illustrated embodiment, a single first and second top plate 37, 38, and a single header 39, extend along the entire length of the side wall assembly 15. The continuous extension of the first and second top plates 37, 38 and header 39 provides increased structural rigidity to the side wall assembly 15 at the top of the side wall assembly. The second stud 25B terminates at a bottom of the third top plate 41 disposed at one of the ends of the top plate assembly 21. The first studs 25A extend past the third top plates 41 and terminate at the bottom of the second top plate 38 such that the third top plates are spaced apart by the first studs. In particular, the first studs 25A include notches 32 at top end margins to configure the top end margins of the first studs to extend past the header 39 to the third top plate 41 and to allow the header 39 to extend continuously across the side wall assembly 15. The notches 32 allow the first studs 25A to engage a major surface of the header 39. Multiple fasteners (e.g., three screws) can be driven through the portion of the first stud 25A overlying the major surface of the header 39 and into the header. The spaced apart relation of the fastener connections of the portion of the first stud 25A overlying the major surface of the header 39 provides a moment couple that strongly resists racking of the studs. The construction of the top plate assembly 21 and bottom plate assembly 23 also permits each module to support and transfer lateral loads applied to the modules 12 when assembled together to form a building.
[0063] Configuring the first studs 25A and the header 39 in the manner described above also allows for additional plumbing components to be included within the footprint of the side wall assembly 15. For instance, a 3-inch (7.6 cm) deep/thick side wall assembly 15 will be configured to allow plumbing to turn from the side wall to the ceiling 13 by penetrating the plumbing through the header 39 without compromising the overall structural stability of the module 12. A width or thickness of the second and third top plates 38, 41 is greater than a width/thickness of the header 39 such that the top plate assembly 21 defines a plurality of top recesses 43 spaced along the length of the side wall assembly 15. Fasteners 44 (FIG. 31C) extending through the first, second, and third top plates 37, 38, 41 may attach the header 39 to the first, second, and third top plates. In one embodiment, the fasteners 44 comprise 5-inch (12.7 cm) screws. Other suitable fasteners may be used.
[0064] Referring to FIGS. 9 and 10, the end wall assembly 19 comprises a top plate 45, a bottom plate 47, a plurality of vertical members or studs 49 extending between the top and bottom plates, and noggins 51 extending between the studs. The top and bottom plates 45, 47 extend parallel to each other, the studs 49 extend parallel to each other, and the noggins 51 extend parallel to each other. The studs 49 are disposed entirety between the top and bottom plates 45, 47 such that the studs extend from a top surface of the bottom plate to a bottom surface of the top plate. At least one header 53 may also extend along the length of the end wall assembly 19 between a pair of studs 49 and together with a sill 55 disposed below the header and extending between the same two studs define an opening (i.e., window opening) in the end wall assembly. Support blocks 57 may also be provided on a bottom surface of the top plate 45 and/or a top surface of the bottom plate 47. The end wall assembly 19 could have other configurations without departing from the scope of the disclosure.
[0065] The length of the top and bottom plates 45, 47 may also define a width of the first module 12A horizontal spacing between the studs 49 may vary. It will be understood that these dimensions are exemplary only, and that the components of the end wall assembly 19 may have other dimensions and spacing depending on the desired size and shape of the module 12. In the illustrated embodiment, each of the top and bottom plates 45, 47, the studs 49, noggins 51, sills 55, and support blocks 57 are comprised entirely of rectangular wood members. A lintel 53 is provided above a door opening in the end wall assembly 19. However, the end wall assembly components could have other configurations without departing from the scope of the disclosure.
[0066] Referring to FIG. 11, the ceiling assembly 13 comprises a plurality of parallel ceiling joists 61 extending across a width of the ceiling assembly and spaced apart along a length of the ceiling assembly, a pair of ceiling plates 62 disposed at opposite sides of the ceiling assembly and extending along the length of the ceiling assembly, and a plurality of ceiling panels 63 covering the joists and plates. In the illustrated embodiment, the joists 61 and plates 62 comprise rectangular wood members. However, the joists 61 and plates 62 could have other configurations without departing from the scope of the disclosure. The joists 61 are attached to inner sides of the ceiling plates 62 to couple the joists together thereby forming the ceiling assembly 13.
[0067] A horizontal spacing between the joist 61 along the length of the ceiling assembly 13 may vary. It will be understood that these ranges are exemplary only, and that the components of the ceiling assembly 13 may have other dimensions and spacing depending on the desired size and shape of the module 12. The joists 61 preferably extend in a direction perpendicular to the axis along which the wall assemblies 15 extend.
[0068] Referring to FIG. 4, the floor assembly 17 comprises a plurality of parallel floor joists 71 spaced apart along a length of the floor assembly, a pair of floor plates 72 (only one is shown) disposed at opposite sides of the floor assembly and extending along the length of the floor assembly, and a plurality of floor panels 73 covering the joists and floor plates. The floor assembly 17 is configured similarly to the ceiling assembly 13. In particular, floor joists 71 extend across a width of the floor assembly 17. However, in the illustrated embodiment, the joists 71 comprise rectangular truss assemblies including a plurality of truss members. The joists 71 could have other configurations without departing from the scope of the disclosure. The joists 71 are attached to inner sides of the floor plates 72 to couple the joists together thereby forming the floor assembly 17.
[0069] A horizontal spacing between the joists 71 may vary. It will be understood that these ranges are exemplary only, and that the components of the floor assembly 17 may have other dimensions and spacing depending on the desired size and shape of the module 12. The joists 71 preferably extend in a direction perpendicular to the axis along which the wall assemblies 15 extend. The floor joists 71 could still have other configurations without departing from the scope of the disclosure.
[0070] Referring to FIG. 8, the floor assembly 17 is attached to the side wall assemblies 15 along the sides of the floor assembly by fasteners 75. In the illustrated embodiment, the fasteners 75 comprise screws (e.g., 3-inch (7.6 cm) screws). Other suitable fasteners may be used. The fasteners 75 attach the bottom plate assemblies 23 of the side wall assemblies 15 to the floor plates 72 of the floor assembly 17. In particular, the fasteners 75 are inserted through the header 29 of the side wall assemblies 15 and into the floor plates 72 of the floor assembly 17. The fasteners 75 are positioned at locations between the floor joists 71 so that the fasteners do not extend through the floor joists. In the illustrated embodiment, each header section between the first studs 25A includes a plurality of fasteners 75 vertically spaced along the header. For example, each header section includes a single column of fasteners 75 having a 3-inch (7.6 cm) spacing between each adjacent fastener. However, the fasteners 75 could be otherwise arranged on the header 29 without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 17 to the side wall assemblies 15 could be utilized without departing from the scope of the disclosure.
[0071] Referring to FIGS. 10 and 12A-12C, the end wall assembly 19 is attached to the side wall assemblies 15 along the sides of the end wall assembly by fasteners 77, and attached to the floor assembly 19 at an end of the floor assembly by fasteners 79. In the illustrated embodiment, the fasteners 77 comprise screws (e.g., 5-inch (12.7 cm) screws). The fasteners 77 attach the corner posts 25C of the side wall assemblies 15 to end studs 49 of the end wall assembly 19. In particular, the fasteners 77 are inserted through the corner posts 25C of the side wall assemblies 15 and into the end studs 49 of the end wall assembly 19. In the illustrated embodiment, the fasteners 77 are arranged in horizontally spaced pairs where each pair is vertically spaced along the height of the side wall assemblies 15. For example, each adjacent fastener pair is spaced about 12 inches (30.5 cm) apart. However, the fasteners 77 could be otherwise arranged on the corner posts 25C without departing from the scope of the disclosure. Additionally, other means of attaching the end wall assembly 19 to the side wall assemblies 15 could be utilized without departing from the scope of the disclosure.
[0072] Referring to FIG. 10, the fasteners 79 comprise screws (e.g., 3-inch (7.6 cm) screws). Other suitable fasteners may be used. The fasteners 79 attach a bottom portion of the end wall assembly 19 to the floor joists 71 of the floor assembly 17. In particular, the fasteners 79 are inserted through the support blocks 57 on the bottom plate 47 of the end wall assembly 19 and into the floor joists 71 of the floor assembly 17. In the illustrated embodiment, each support block 57 includes a pair of fasteners 79 horizontally spaced across the support block. For example, each fastener pair may have an 8-inch (20.3 cm) spacing between the fasteners 79. However, the fasteners 79 could be otherwise arranged on the support blocks 57 without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 17 to the end wall assembly 19 could be utilized without departing from the scope of the disclosure. The floor panels 73 may be attached to the floor joist 71 by fasteners (not shown). In one embodiment, the fasteners comprise 10d nails.
[0073] Referring to FIGS. 11, 13A, and 13B, the ceiling assembly 13 is attached to the side wall assemblies 15 along the sides of the ceiling assembly by fasteners 75. In the illustrated embodiment, the fasteners 75 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 75 attach the top plate assemblies 21 of the side wall assemblies 15 to the ceiling plates 62 of the ceiling assembly 13. In particular, the fasteners 75 are inserted through the header 39 of the top plate assemblies 21 of the side wall assemblies 15 and into the ceiling plates 62 of the ceiling assembly 13. The fasteners 75 are positioned at locations between the ceiling joists 61 so that the fasteners do not extend through the ceiling joists. In the illustrated embodiment, each header section between the first studs 25A includes a plurality of fasteners 75 vertically spaced along the header. For example, each header section includes a single column of fasteners 75 having a 2-inch (5 cm) spacing between each adjacent fastener. However, the fasteners 75 could be otherwise arranged on the header 29 without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 13 to the side wall assemblies 15 could be utilized without departing from the scope of the disclosure.
[0074] Referring to FIGS. 14A and 14B, the fasteners 79 attach a top portion of the end wall assembly 19 to the ceiling joists 61 of the ceiling assembly 13. In particular, the fasteners 79 are inserted through the support blocks 57 on the top plate 45 of the end wall assembly 19 and into the ceiling joists 61 of the ceiling assembly 13. In the illustrated embodiment, each support block 57 includes a pair of fasteners 79 horizontally spaced across the support block. For example, each fastener pair may have an 8-inch (20.3 cm) spacing between the fasteners 79. However, the fasteners 79 could be otherwise arranged on the support blocks 57 without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 13 to the end wall assembly 19 could be utilized without departing from the scope of the disclosure. The ceiling panels 63 may be attached to the side wall assemblies 15 by fasteners 81 such that the ceiling panels cover the ceiling joist 61 (FIG. 13B). In one embodiment, the fasteners 81 comprise 10d nails or other suitable fasteners.
[0075] Referring to FIGS. 1-3, the second module 14 of the module assembly 11 comprises a pair of side wall assemblies 115, a ceiling assembly 113 attachable to tops of the side wall assemblies, a floor assembly 117 attachable to bottoms of the side wall assemblies, and an end wall assembly 119 attachable to the side wall assemblies, floor assembly, and ceiling assembly. The side wall assemblies 115, and end wall assembly 119, are configured to support the floor assembly 117 and ceiling assembly 113 such that floor assembly and ceiling assembly may be hung from sides of the wall assemblies. Thus, the second module 14, like the first module 12, can be suitably erected by separately attaching the wall assemblies 115, 119 to the floor assembly 117 and then attaching the ceiling assembly 113 to the wall assemblies. Other orders of attachment of the assemblies 113, 115, 117, 119 are also envisioned without departing from the scope of the disclosure. In one embodiment, the second module 14 incorporates balloon framing in the construction of the module, similar to that of the first module 12.
[0076] Referring to FIGS. 1-3 and 15, each side wall assembly 115 comprises a top plate assembly or beam assembly 121, a bottom plate assembly or beam assembly 123, and a plurality of vertical members or studs 125A, 125B, 125C extending between the top and bottom plate assemblies. The top and bottom plate assemblies 121, 123 extend parallel to each other, and the studs 125A, 125B, 125C extend parallel to each other. First studs 125A make up the majority of the studs and are spaced inward from the longitudinal ends of the top and bottom plate assemblies 121, 123. The first studs 125A extend into the top and bottom plate assemblies 121, 123 such that the first studs extend past a bottom of the top plate assembly and below a top of the bottom plate assembly. One of the second studs 125B at least partially defines one of the ends of the side wall assembly 115. The second studs 125B are disposed entirety between the top and bottom plate assemblies 121, 125 such that the second studs extend from a top surface of the bottom plate assembly to a bottom surface of the top plate assembly. As will be explained in greater detail below, this configuration facilities attachment of the second module 14 to the first module 12. A partition stud 125C may also be provided opposite one of the second studs 125B. Noggins 126 (FIG. 27) may also be provided in the side wall assemblies 115. In the illustrated embodiment, a first end of the top and bottom plate assemblies 121, 123 is flush with one of the second studs 125B at one end of the side wall assembly, and a second end of the top and bottom plate assemblies extends laterally past the second stud 125B at the opposite end of the side wall assembly 115. The first end is configured for attachment to the first module 12, and the second end is configured for attachment to the third module 16, as will be discussed in greater detail below.
[0077] The length of the top and bottom plate assemblies 121, 123 may also define a length of the second module 14A horizontal spacing between the studs 125A, 125B, 125C may vary. It will be understood that these dimensions are exemplary only, and that the components of the side wall assemblies 115 may have other dimensions and spacing depending on the desired size and shape of the module 14. In the illustrated embodiment, each of the top and bottom plate assemblies 121, 123 and the studs 125A, 125B, 125C are comprised entirely of rectangular wood members. However, the plate assemblies 121, 123 and studs 125A, 125B, 125C could have other configurations without departing from the scope of the disclosure.
[0078] Referring to FIGS. 15 and 16, the bottom plate assembly 123 may comprise a first bottom plate 127 defining a bottom of the side wall assembly 115, a header 129 disposed on top of the first bottom plate, and a plurality of spaced apart second bottom plates 128 disposed on the header. In the illustrated embodiment, a single first bottom plate 127 and single header 129 extend along the entire length of the side wall assembly 115. In the illustrated embodiment, an end of the header 129 extends outward from the partition stud 125C and is free of a second bottom plate 128. The portion of the header 129 extending past the partition stud 125C has a length that is configured for attaching the side wall assemblies 115 to another module as will be discussed in greater detail below. The second stud 125B seats on top of one of the second bottom plates 128 disposed on one of the ends of the bottom plate assembly 123. The first studs 125A extend past the second bottom plates 128 and seat on top of the first bottom plate 127 such that the second bottom plates are spaced apart by the first studs. In particular, the first studs 125A include notches at bottom end margins to configure the bottom end margins of the studs to extend past the header 129 to the first bottom plate 127. A width or thickness of the first and second bottom plates 127, 128 and first studs 125A is greater than a width/thickness of the header 129 such that the bottom plate assembly 123 defines a plurality of bottom recesses 130 spaced along the length of the side wall assembly 115. Fasteners 136 (FIGS. 31A and 31B) extending through the first and second bottom plates 127, 128 may attach the header 129 to the first and second bottom plates. In one embodiment, the fasteners 136 comprise 3-inch (7.6 cm) screws. Other suitable fasteners may be used.
[0079] The top plate assembly 121 may comprise first top plates 137 defining a top of the side wall assembly 115, a second top plate 138 disposed on a bottom of the first top plates, a header 139 disposed on a bottom of the second top plate, and a plurality of third top plates 141 disposed on bottoms of the header. In the illustrated embodiment, two first top plates 137 are spaced apart by a gap aligned with the partition stud 125C, and a single second top plate 138 and a single header 139 extend along the entire length of the side wall assembly 115 (FIG. 15). In the illustrated embodiment, an end of the header 139 extends outward from the partition stud 125C and is free of a third top plate 141. The portion of the header 139 extending past the partition stud 125C has a length that is configured for attaching the side wall assemblies 115 to another module as will be discussed in greater detail below. The second studs 125B contact a bottom of the third top plates 141 disposed on the ends of the top plate assembly 121. The first studs 125A extend past the third top plates 141 and contact the bottom of the second top plate 138 such that the third top plates are spaced apart by the first studs. In particular, the first studs 125A include notches at top end margins to configure the top end margins of the studs to extend past the header 139 to the second top plate 138. A width or thickness of the second and third top plates 138, 141 is greater than a width/thickness of the header 139 such that the top plate assembly 121 defines a plurality of top recesses 142 spaced along the length of the side wall assembly 115. Fasteners 144 (FIG. 31C) extending through the first, second, and third top plates 137, 138, 141 may attach the header 139 to the first, second, and third top plates. In one embodiment, the fasteners 144 comprise 5-inch (12.7 cm) screws. Other suitable fasteners may be used.
[0080] Referring to FIGS. 17 and 18, the end wall assembly 119 comprises a first top plate 145, a second top plate 146 a bottom plate 147, a plurality of vertical members or studs 149 extending between the top and bottom plates, and noggins 151 extending between the studs. The top and bottom plates 145, 146, 147 extend parallel to each other, the studs 149 extend parallel to each other, and the noggins 151 extend parallel to each other. The studs 149 are disposed entirety between the second top plate 146 and the bottom plate 147 such that the studs extend from a top surface of the bottom plate to a bottom surface of the second top plate. At least one header 153 may also extend along the length of the end wall assembly 119 between studs 149 and together with a footer 154 disposed below the header and extending between the same two studs define an opening (i.e., door opening) in the end wall assembly. Support blocks 157 may also be provided on a bottom surface of the second top plate 146 and/or a top surface of the bottom plate 147. In the illustrated embodiment, the first top plate 145 extends laterally past the studs 149 on both sides of the end wall assembly 119. The location and size of the gap between the first top plates 137 described above is precisely controlled. As a result, the top plate 145 of the end wall 119 is received in the gap (see, FIG. 22). In this way the position of the end wall 119 is precisely controlled without measuring. Proper location of the end wall assembly 119 and the wall assemblies 115 is achieved upon placing the top plate 145 in the gaps between first top plates 137 of the wall assemblies. The end wall assembly 119 could have other configurations without departing from the scope of the disclosure.
[0081] The length of the top and bottom plates 145, 146, 147 may also define a width of the second module 14. A horizontal spacing between the studs 149 may vary. It will be understood that these dimensions are exemplary only, and that the components of the end wall assembly 119 may have other dimensions and spacing depending on the desired size and shape of the module 14. In the illustrated embodiment, each of the top and bottom plates 145, 146, 147, the studs 149, noggins 151, header 153, footer 154, and support blocks 157 are comprised entirely of rectangular wood members. However, the end wall assembly components could have other configurations without departing from the scope of the disclosure.
[0082] Referring to FIGS. 19-21, the ceiling assembly 113 comprises a plurality of parallel ceiling joists 161A, 161B extending across a width of the ceiling assembly and spaced apart along a length of the ceiling assembly, a pair of ceiling plates 162 disposed at opposite sides of the ceiling assembly and extending along the length of the ceiling assembly, and a plurality of ceiling panels 163 covering the joists and plates. First joists 161A extend partially across the ceiling assembly 113 along a first width segment of the ceiling assembly, and second joist 161B extend from the first joists partially across the ceiling assembly along a second width segment of the ceiling assembly. Together, each pair of ceiling joists 161A, 161B extends across the entire width of the ceiling assembly 113. In the illustrated embodiment, the first joists 161A comprise truss assemblies having a first height, and the second joists 161B comprise truss assemblies having a second height that is greater than the first height. However, the joists 161A, 161B could have other configurations without departing from the scope of the disclosure. The joists 161A, 1161B are attached to inner sides of the ceiling plates 162 to couple the joists together thereby forming the ceiling assembly 113.
[0083] A horizontal spacing between the joist pairs 161A, 161B along the length of the ceiling assembly 113 may vary. It will be understood that these ranges are exemplary only, and that the components of the ceiling assembly 113 may have other dimensions and spacing depending on the desired size and shape of the module 14. The joists 161A, 161B preferably extend in a direction perpendicular to the axis along which the wall assemblies 115 extend. In the illustrated embodiment, each of the first and second ceiling joists 161A, 161B comprise rectangular truss assemblies including a plurality of truss members. In one embodiment, the first and second ceiling joists 161A, 161B comprise posi-joists made my MiTek Inc. of Chesterfield, MO. The ceiling joists 161A, 161B could have other configurations without departing from the scope of the disclosure.
[0084] Referring to FIGS. 20 and 21, the second ceiling joists 161B include MEP (mechanical, electrical, and plumbing) supports incorporated into the joists to assist in the installation of MEP components 164 into the module 14. In the illustrated embodiment, the MEP supports comprise one or more support blocks 165 attached to the truss members of the joists 161B. For example, the ceiling joists 161B may comprises longitudinal truss members extending along a length of the ceiling joist, and transverse truss members extending between the longitudinal truss members. The support blocks 165 may be mounted on the longitudinal truss members between two adjacent transverse truss members. Thus, the support blocks 165 comprise additional structure to the truss members that make up the structural support of the joist 161B. The support blocks 165 provide a support surface for supporting the MEP components 164 extending through the joists 161B. The support blocks 165 may have various sizes and/or may be combined (e.g., stacked on top of each other) to locate the support surfaces of the support blocks at the proper heights for the MEP components 164, thereby to position the MEP components within the truss members. In one embodiment, the support blocks 165 comprises indicia 167 for instructing an installer what MEP component(s) is to be positioned at this location. Further, the indicia 167 inform the installer where and how to extend the MEP components 164 through the joists 161B. For example, the indicia 167 may comprise colored markings, arrows, writing, etc. describing to the installer which MEP components 164 to run along the support blocks 165 and in which direction and pitch to extend the MEP components. More specifically, the MEP components 164 and 165 are sized and shaped so that upon installation, pipes installed in the ceiling assembly 113 and resting on the MEP components automatically have the proper slope (e.g., as for gravity draining). Therefore, the MEP components 164 can be pre-installed in the ceiling assembly 113 prior to attaching the ceiling assembly to the other assemblies of the module. Similar indicia may also be provided on the wall assemblies 115 to instruct the installation of electrical/plumbing components. Additionally, the ceiling assembly 13 of the first module 12 may be equipped with MEP supports.
[0085] Referring to FIG. 15, the floor assembly 117 comprises a plurality of parallel floor joists (not shown) spaced apart along a length of the floor assembly, floor plates 172 attached to sides of the floor joists and disposed around a perimeter of the floor assembly, and a plurality of floor panels 173 covering the joists and floor plates. The floor assembly 117 is configured similarly to the floor assembly 17 of the first module 12. In particular, floor joists extend across a width of the floor assembly 117. In one embodiment, the joists may comprise rectangular wooden members. In another embodiment, the joists may comprise rectangular truss assemblies. The joists could have other configurations without departing from the scope of the disclosure. The joists are attached to inner sides of the floor plates 172 to couple the joists together thereby forming the floor assembly 117.
[0086] Referring to FIGS. 15 and 16, the floor assembly 117 is attached to the side wall assemblies 115 along the sides of the floor assembly by fasteners 175. In the illustrated embodiment, the fasteners 175 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 175 attach the bottom plate assemblies 123 of the side wall assemblies 115 to the floor plates 172 of the floor assembly 117. In particular, the fasteners 175 are inserted through the header 129 of the side wall assemblies 115 and into the floor plates 172 of the floor assembly 117. The fasteners 175 are positioned at locations between the floor joists so that the fasteners do not extend through the floor joists. In the illustrated embodiment, each header section between the studs 125A includes a plurality of fasteners 175 vertically spaced along the header section. For example, each header section includes a single column of fasteners 175 having a 3-inch (7.6 cm) spacing between each adjacent fastener. However, the fasteners 175 could be otherwise arranged on the header 129 without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 117 to the side wall assemblies 115 could be utilized without departing from the scope of the disclosure.
[0087] Referring to FIGS. 17, 18, and 22-23B, the end wall assembly 119 is attached to the side wall assemblies 115 along the sides of the end wall assembly by fasteners 177, and attached to the floor assembly 119 at an end of the floor assembly by fasteners 179. In the illustrated embodiment, the fasteners 177 comprise screws (e.g., 5-inch (12.7 cm) screws). The fasteners 177 attach the partition studs 125C of the side wall assemblies 115 to end studs 149 of the end wall assembly 119. In particular, the fasteners 177 are inserted through the partition studs 125C of the side wall assemblies 115 and into the end studs 149 of the end wall assembly 119. In the illustrated embodiment, the fasteners 177 are arranged in horizontally spaced pairs where each pair is vertically spaced along the height of the side wall assemblies 115. For example, each adjacent fastener pair is spaced about 12 inches (30.5 cm) apart. However, the fasteners 177 could be otherwise arranged on the partition studs 125C without departing from the scope of the disclosure. Additionally, other means of attaching the end wall assembly 119 to the side wall assemblies 115 could be utilized without departing from the scope of the disclosure
[0088] Referring to FIGS. 17 and 18, the fasteners 179 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 179 attach a bottom portion of the end wall assembly 119 to the floor plates 172 of the floor assembly 117. In particular, the fasteners 179 are inserted through the bottom noggins 151 of the end wall assembly 119 and into a floor plate 172 of the floor assembly 117. In the illustrated embodiment, each noggin 151 includes a pair of fasteners 179 horizontally spaced across the noggin. For example, each fastener pair may have an 8-inch (20.3 cm) spacing between the fasteners 179. However, the fasteners 179 could be otherwise arranged on the noggins 151 without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 117 to the end wall assembly 119 could be utilized without departing from the scope of the disclosure.
[0089] Referring to FIGS. 24-25B, the ceiling assembly 113 is attached to the side wall assemblies 115 along the sides of the ceiling assembly by fasteners 178. In the illustrated embodiment, the fasteners 178 comprise screws (e.g., 5-inch (12.7 cm) screws) or other suitable fasteners. The fasteners 178 attach the top plate assemblies 121 of the side wall assemblies 115 to the ceiling assembly 113. In particular, the fasteners 178 are inserted through pre-drilled holes in the first and second top plates 137, 138 of the top plate assemblies 121 and the studs 125A of the side wall assemblies 115 and into the ceiling plates 162 of the ceiling assembly 113. In the illustrated embodiment, the first and second top plates 137, 138 include a plurality of fasteners 178 horizontally spaced along the top plates. For example, the first and second top plates 137, 138 each include a single row of fasteners 178 having a 12-inch (30.5 cm) spacing between adjacent fasteners. A third row of fasteners 178 having a greater than 12-inch (30.5 cm) spacing between adjacent fasteners is provided in the studs 125A. However, the fasteners 178 could be otherwise arranged on the side wall assemblies 115 without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 113 to the side wall assemblies 115 could be utilized without departing from the scope of the disclosure.
[0090] In some embodiments, the ceiling assembly 13, 113 may be positioned and at least temporarily held in place on the wall assemblies 15, 115. The top plate 37, 137 may be broken up into segments, leaving gaps between adjacent segments of the top plate. The location and size of these gaps can be precisely controlled. When the ceiling assembly 13, 113 an extended-length top chord of the ceiling joist 161A, 161B that are located on opposite ends of the ceiling assembly can be placed into the gap. This act results in the ceiling assembly 13, 113 being located precisely in the proper position with respect to the wall assemblies 15, 115 without measuring by the workers assembling the module 12, 112. This can be seen with regard to FIG. 3 in an upper left hand corner of the drawing. Another advantage of this construction is that the ceiling assembly 13, 113 can be self-shoring. The ceiling assembly 13, 113 can be temporarily held in place by the wall assemblies 15, 115 until fasteners permanently connect these components together.
[0091] Referring to FIG. 26, fasteners 179 also attach a top portion of the end wall assembly 119 to a ceiling plate 162 of the ceiling assembly 113. In particular, the fasteners 179 are inserted through the support blocks 157 on the top plate 145 of the end wall assembly 119 and into the ceiling plate 162 of the ceiling assembly 113. In the illustrated embodiment, each support block 157 includes a pair of fasteners 179 horizontally spaced across the support block. For example, each fastener pair may have an 8-inch (20.3 cm) spacing between the fasteners 179. However, the fasteners 179 could be otherwise arranged on the support blocks 157 without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 113 to the end wall assembly 119 could be utilized without departing from the scope of the disclosure.
[0092] Referring to FIGS. 27-30B, a third module 16 is attachable to an end of the second module 14 opposite the end of the second module to which the first module is attached. In one embodiment, the third module 16 comprises a corridor frame. Thus, the third module 16 may serve as a connecting module between two module assemblies 11, 11. As such, the third module 16 may be considered part of a module assembly 11, 11 or a separate module for connecting two module assemblies. For example, the third module 16 may connect two module assemblies 11, 11 in an end-to-end fashion as shown in FIG. 32.
[0093] The third module 16 may comprise a corridor floor assembly 217 attachable to a bottom of the second module 14, and a corridor ceiling assembly 213 attachable to a top of the second module. The ceiling assembly 213 comprises a plurality of parallel ceiling joists 261 extending across a width of the ceiling assembly and spaced apart along a length of the ceiling assembly, a pair of ceiling plates 262 disposed at opposite sides of the ceiling assembly and extending along the length of the ceiling assembly, and a plurality of ceiling panels 263 covering the joists and plates. In the illustrated embodiment, the joists 261 comprise rectangular wood members. However, the joists 261 could have other configurations without departing from the scope of the disclosure. The joists 261 are attached to inner sides of the ceiling plates 262 to couple the joists together thereby forming the ceiling assembly 213
[0094] The floor assembly 217 comprises a plurality of parallel floor joists 271 spaced apart along a length of the floor assembly, a pair of floor plates 272 disposed at opposite sides of the floor joists and extending along the length of the floor assembly, and a plurality of floor panels 273 covering the joists and floor plates. The floor assembly 217 is configured similarly to the ceiling assembly 213. In particular, floor joists 271 extend across a width of the floor assembly 217. In the illustrated embodiment, the joists 271 comprise rectangular wood members. However, the joists 271 could have other configurations without departing from the scope of the disclosure. The joists 271 are attached to inner sides of the floor plates 272 to couple the joists together thereby forming the floor assembly 217.
[0095] Referring to FIGS. 27-28B, the floor assembly 217 of the third module 16 is attached to the side wall assemblies 115 of the second module 14 at sides of the floor assembly by fasteners 177, and attached to the end wall assembly 119 of the second module at an end of the floor assembly by fasteners 179. In the illustrated embodiment, the fasteners 177 comprise screws (e.g., 5-inch (12.7 cm) screws). The fasteners 177 attach the bottom plate assemblies 123 of the side wall assemblies 115 to the floor assembly 217. A splice plate 185 is placed over the header 129 so that the header is sandwiched between the splice plate 185 and the end floor joist 271. In particular, the fasteners 177 are inserted through the splice plate 185, the header 129 of the side wall assemblies 115 and into the end floor joists 271 of the floor assembly 217 (FIG. 28A). In the illustrated embodiment, the fasteners 177 are arranged in vertically spaced pairs where each pair is horizontally spaced along the length of the side wall assemblies 115. For example, each adjacent fastener pair is spaced greater than 12 inches (30.5 cm) apart. However, the fasteners 177 could be otherwise arranged on the header 129 without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 217 to the side wall assemblies 115 could be utilized without departing from the scope of the disclosure.
[0096] Referring to FIGS. 27 and 28B, the fasteners 179 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 179 attach a bottom portion of the end wall assembly 119 to the floor plates 272 of the floor assembly 217. In particular, the fasteners 179 are inserted through pre-drilled holes in the floor plates 272 of the floor assembly 217 and into the studs 149 of the end wall assembly 119. In the illustrated embodiment, a pair of vertically spaced fasteners 179 are driven into the studs 149. For example, each fastener pair may have a 4-inch (10 cm) spacing between the fasteners 179. However, the fasteners 179 could be otherwise arranged without departing from the scope of the disclosure. Additionally, other means of attaching the floor assembly 217 to the end wall assembly 119 could be utilized without departing from the scope of the disclosure.
[0097] Referring to FIGS. 29-30B, the ceiling assembly 213 is attached to the side wall assemblies 115 along the sides of the ceiling assembly by fasteners 177. In the illustrated embodiment, the fasteners 177 comprise screws (e.g., 5-inch (12.7 cm) screws). The fasteners 177 attach the top plate assemblies 121 of the side wall assemblies 115 to the ceiling assembly 213. In particular, the fasteners 177 are inserted through the header 139 of the side wall assemblies 115 and into the end ceiling joists 261 of the ceiling assembly 213. In the illustrated embodiment, the fasteners 177 are arranged in vertically spaced pairs where each pair is horizontally spaced along the length of the side wall assemblies 115. For example, each adjacent fastener pair is spaced greater than 12 inches (30.5 cm) apart. However, the fasteners 177 could be otherwise arranged on the header 139 without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 213 to the side wall assemblies 115 could be utilized without departing from the scope of the disclosure.
[0098] Referring to FIGS. 30A and 30B, fasteners 179 attach a top portion of the end wall assembly 119 to a ceiling plate 262 of the ceiling assembly 213. In particular, the fasteners 179 are inserted through pre-drilled holes in the ceiling plate 262 of the ceiling assembly 213 and into the studs 149 of the end wall assembly 119. In the illustrated embodiment, a pair of vertically spaced fasteners 179 are driven into the studs 149. For example, each fastener pair may have a 4-inch (10 cm) spacing between the fasteners 179. However, the fasteners 179 could be otherwise arranged without departing from the scope of the disclosure. Additionally, other means of attaching the ceiling assembly 213 to the end wall assembly 119 could be utilized without departing from the scope of the disclosure.
[0099] Referring to FIGS. 1-3 and 31A-31C, the first module 12 can be attached to the second module 14 along the top and bottom plate assemblies 21, 23, 121, 123 of the first and second modules. In particular, a top splice plate (not shown) may be used to attach the top plate assemblies 21, 121 of the first and second modules 12, 14, respectively, and a bottom splice plate 85 may be used to attach the bottom plate assemblies 23, 123 of the first and second modules, respectively (FIG. 31A). The top splice plate is received in recesses 43 at a module connection end of the first module 12 and the recess 142 at a module connection end of the second module 14 when the first and second modules are placed in abutment (FIG. 1). Similarly, the bottom splice plate 85 is received in recesses 33 at the module connection end of the first module 12 and the recess 130 at the module connection end of the second module 14 when the first and second modules are placed in abutment. Fasteners 87 are received through the top and bottom splice plates and into the headers 29, 39 to secure the splice plates to the top and bottom plate assemblies 21, 23, 121, 123, and thereby secure the first and second modules 12, 14 together. In the illustrated embodiment, the splice plates comprise rectangular plate members. However, the splice plates could have other configurations without departing from the scope of the disclosure. Additionally, only a single splice plate (either top or bottom splice plate) may be utilized to connect the first and second modules 12, 14. Thus, a single rectangular connection plate may be provided for attaching the modules 12, 14 together.
[0100] Referring to FIG. 32, a first module assembly 11 may be attached to a second module assembly 11 to form a double-module assembly configuration. To begin, the third module 16 may be attached to the second module 14 of the first module assembly 11. For example, the floor assembly 217 of the third module 16 is attached to end wall assembly 119 of the second module 14 of the first module assembly 11 as previously described. The ceiling assembly 213 of the third module 16 is then attached to the end wall assembly 119 of the second module 14 of the first module assembly 11 as was also previously described. The second module assembly 11 can then be attached to the third module 16 at the opposite side from the first module assembly 11. In particular, the second module 14 of the second module assembly 11 can be attached to the third module 16 as was previously described for the first module assembly 11. Thus, the first and second module assemblies 11, 11 will be attached end-to-end in a face-to-face orientation with the third module 16 forming the framework for a hallway between the two module assemblies. As such, multiple double-module assemblies can be arranged side-by-side to form the framework for a single floor of an apartment building/hotel. Additionally, the first and second module assemblies 11, 11 can be shipped in pairs to facilitate erecting of a building including multiple pairs of the module assemblies.
[0101] When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles a, an, the and said are intended to mean that there are one or more of the elements. The terms comprising, including and having are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0102] In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
[0103] As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
