Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS, SYSTEMS AND METHODS FOR
MODULAR CONSTRUCTION
Related Application
[0001] This application claims priority to U.S. provisional application no.
61/570,656
filed 14 December 2011.
Technical Field
[0002] The invention relates to modular construction of buildings. Embodiments
of the
invention provide volumetric construction modules, methods for assembling such
modules into buildings, and buildings and structural components of buildings
constructed
from such modules.
Background
[00031 Modular building construction has many advantages over conventional
building
construction. For example, prefabricated construction sections can be
manufactured away
from construction sites at centralized factories, which may permit more
productive use of
time, labour, material and equipment. Modular construction also presents fewer
logistical
challenges than conventional construction by marshalling and assembling
materials,
devices and equipment off site in factory conditions and thereby reducing the
variety of
materials and components required during construction and by permitting
efficient
division and scheduling of on-site construction tasks. Modular construction
may also be
performed with less extensive site preparation, and can streamline the process
of
obtaining engineering approval. These and other advantages of modular
construction may
be especially pronounced in the construction of multi-story buildings. For
instance,
modular construction may allow for a smaller construction site footprint,
since arranging
just-in-time delivery of and storage for fewer and less various prefabricated
construction
sections is simpler than for more diverse materials and components used in
conventional
construction.
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[0004] Additional economic advantages may be realized in modular construction
by
using prefabricated volumetric construction modules. For example,
prefabricated
volumetric construction modules may allow pre-installation (e.g., before
delivery to the
construction site or at the construction site before placement of the module
in the
building) of utility connections (e.g., plumbing, electricity wiring, HVAC,
fire protection,
etc.), interior finishing (e.g., kitchen fixtures, bathroom fixtures,
cabinetry, drywall,
curtain walls, etc.), and fenestration hardware (e.g., doors, windows, casings
therefore,
etc.). Prefabricated volumetric construction modules may also be configured to
accord
with the dimensions of intermodal shipping containers, thereby simplifying and
economizing transportation, handling and assembly of the modules.
[0005] Building codes in much of the world require buildings to meet minimum
structural strength criteria. In some areas of the world, building codes
require buildings to
meet structural strength and stiffness criteria sufficient to withstand the
loads that occur
during seismic events. It is a challenge to construct multi-story buildings
that have
adequate structural strength from prefabricated structural sections without
incurring costs
that extinguish the economic advantages of modular construction. The challenge
of
constructing multi-story buildings is especially daunting when using
volumetric
construction modules, due to the lack of continuity of the volumetric
construction
modules structural members.
[0006] Most modern residential high rise buildings are built with concrete
reinforced
with rebar. In these buildings it is conventional to provide reinforced
concrete
diaphragms that span shear walls and/or building frames. The concrete
diaphragms
transmit horizontal forces to the shear walls and/or building frames. Though
it is possible
to construct conventional buildings with rebar reinforced concrete walls and
slab
diaphragms around volumetric construction modules employing the modules as
formwork, (such as is described in Published PCT Application no. WO
2009/061702), in
general this is not cost efficient.
[0007] Another aspect of this challenge is the problem of providing vertical
and lateral
load bearing members that are sufficiently strong to support buildings having
at least
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several stories. Currently, it is conventional to provide reinforced concrete
columns by
encasing steel re-bar in concrete. This typically involves casting concrete in
and around
re-bar cages, which requires tying steel re-bar and assembling concrete
formwork around
the rebar on-site. For multi-story buildings, this requires tying steel-rebar,
and placing
and removing concrete forms at progressively higher floors. The connections of
beams to
columns are particularly challenging for rebar installation due to congestion
of rebar
required to counteract the forces concentrated at these locations. Setting,
stripping,
cleaning, rigging and resetting formwork is also time consuming and labour
intensive
particularly for concrete slab soffit forms.
[00081 There is accordingly need for volumetric construction modules, building
systems
and construction methods that facilitate construction of structurally strong
multi-story
buildings from prefabricated volumetric construction modules.
[0009] References in the general field of the technology include the
following:
= CA 2,542,184¨ BUILDING MODULES
= US 3,331,170¨ PREASSEMBLED SUBENCLOSURES ASSEMBLED TO
FORM BUILDING CONSTRUCTION
= US 3,514,910¨ MODULAR BUILDING CONSTRUCTION
= US 4,599,829 ¨ MODULAR CONTAINER BUILDING SYSTEM
= US 5,584,151 ¨ EARTHQUAKE, WIND RESISTANT AND FIRE RESISTANT
PRE-FABRICATED BUILDING PANELS AND STRUCTURES FORMED
THEREFROM
= US 7,827,738 ¨ SYSTEM FOR MODULAR BUILDING CONSTRUCTION
= US 2003/0188507 ¨ METHOD FOR CONSTRUCTING MODULAR
SHELTERS USING RECYCLED LAND/SEA SHIPPING CONTAINERS
= US 2005/0223651 ¨ BARRIER-PROTECTED CONTAINER
= US 2006/0185264 ¨ PREFABRICATED BUILDING METHOD
= US 2008/0307729 ¨ STRUCTURAL PANELS
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= US 2007/0084135 ¨ CONSTRUCTION SYSTEM FOR STEEL-FRAME
BUIDLINGS
= US 2011/0036018 ¨ MOVABLE BUILDING
= WO 2009/061702 ¨ MODULAR BUILDING CONSTRUCTION UNIT,
SYSTEM, AND METHOD
= WO 2009/132387 ¨ FIRE RATED, MULTI-STOREY, MULTI-DWELLING
STRUCTURE AND METHOD TO CONSTRUCT SAME
= WO 2011/15836¨ MODULAR BUILDING AND FOUNDATION SYSTEM
THEREFOR AND METHODS FOR THEIR CONSTRUCTION
= DE 3716795 ¨ FORMWORK FOR AN UNDERGROUND BOMB SHELTER
= FR 2710087 ¨ CONSTRUCTION COMPONENTS AND METHODS FOR
MAKING THEM
= GB 8323946 ¨ PORTABLE BUILDING
= GB 2146053 ¨ PORTABLE BUILDING
= EP 1123449¨ VOLUMETRIC MODULAR BUILDING SYSTE
[0010] The foregoing examples of the related art and limitations related
thereto are
intended to be illustrative and not exclusive. Other limitations of the
related art will
become apparent to those of skill in the art upon a reading of the
specification and a study
of the drawings.
Summary
[0011] The following embodiments and aspects thereof are described and
illustrated in
conjunction with systems, tools and methods which are meant to be exemplary
and
illustrative, not limiting in scope. In various embodiments, one or more of
the above-
described problems have been reduced or eliminated, while other embodiments
are
directed to other improvements.
[00121 An aspect of the invention provides a method of modular building
construction
comprising (a) providing a first volumetric construction module comprising a
frame, the
frame comprising a first segment; (b) defining a volume of a composite segment
and
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integrating the first segment with the volume; and (c) filling the volume with
a curable
material to cast the composite segment. The method may include, prior to step
(b), step
(a)(i) comprising providing a structure adjacent the first volumetric
construction module,
the adjacent structure comprising a second segment, and wherein step (b)
comprises
integrating the first segment and the second segment with the volume. In step
(b) the
volume may contain at least a portion of the first and second segments. Step
(b) may
comprise defining a boundary of the volume with temporary formwork. Step (b)
may
comprise defining at least a portion of the boundary of the volume with the
first and
second segments. The adjacent structure may comprise a second volumetric
construction
module comprising a frame including the second segment. The curable material
may
comprise a high strength curable material, such as carbon fibre reinforced
polymer or
high strength concrete.
[0013] The method may include, prior to step (b), step (a)(ii) comprising
augmenting
structural capacity of the composite segment. Step (a)(ii) may comprise
coupling the first
segment and/or the second segment to a plurality of shear connectors extending
into the
volume. Step (a)(ii) may further comprise coupling a column reinforcement
member to
the plurality of shear connectors. Step (a)(ii) may comprise providing a
column closure
member opposite to the first segment and/or the second segment, the column
closure
member defining a portion of the boundary of the volume. The column closure
member
may be coupled to a plurality of shear connectors extending into the volume.
Step (a)(ii)
may comprise providing a plurality of first and second reinforcement elements,
the first
and second reinforcement elements extending in transverse planes with respect
to each
other. The first reinforcement elements may comprise rebar rods and the second
reinforcement elements comprise rebar stirrups. Step (a)(ii) may further
comprise
providing a plurality of first and second reinforcement elements, wherein the
second
reinforcement elements engage the shear connectors. The first reinforcement
elements
may comprise rebar rods and the second reinforcement elements comprise rebar
stirrups.
Step (a)(ii) may comprise coupling the first segment and the second segment by
wrapping
the segments with fibre reinforced polymer wrap.
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[0014] Each of the first and second volumetric construction modules may have
an
opening defined in its side that faces the other module, wherein the volume
may comprise
a space between the modules adjacent the openings. The volume may comprise a
space
between adjacent corners of the frame of the at least one of the first and
second
volumetric construction modules. The volume may comprise a space adjacent an
edge of
the frame of at least one of the first and second volumetric construction
modules. The
first and second volumetric construction modules may be provided in laterally
adjacent
relation. The first and second volumetric construction modules in laterally
adjacent
relation may comprise providing the modules such that a side of one module is
adjacent a
side of the other module, or such that an end of one module is adjacent a side
of the other
module, or such that an end of one module is adjacent an end of the other
module. The
frame of each of the first and second volumetric construction module may
comprise a
plurality of vertical posts, wherein the volume comprises a space between
opposed posts
of the modules. The frame of each of the first and second volumetric
construction
module may comprise a horizontal rail, wherein the volume comprises a space
between
opposed rails of the modules. Each of the first and second volumetric
construction
module may comprise a panel section fastened to the frame, wherein the volume
comprises a space between opposed panel sections of the modules.
[0015] Adjacent upper portions of the frames may be bridged with a structural
member to
provide a bottom boundary of a slab volume. The structural member may comprise
one
or more upwardly extending shear connectors. The shear connectors may extend
past
the top of the frames. A plurality of rebar rods and rebar stirrups may be
provided in the
slab volume. The structural member may comprise a hot or cold rolled steel
section, such
as a plate, I beam or truss. A boundary of the slab volume may be partially
defined by a
spacer installed above the first volumetric construction module and/or the
second
volumetric construction module. The top corners of the frame of each of the
first and
second volumetric construction modules may comprise corner fittings having
upper
orifices, wherein the spacer comprises at least one downward projection, and
wherein
installing the at least one spacer comprises mating the at least one downward
projection
with one of the upper orifices. A curable material may be introduced to the
slab volume.
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An upper volumetric construction module may be provided above each of the
first and
second volumetric construction modules, each of the upper volumetric
construction
modules comprising a frame. At least bottom corners of the frame of each upper
module
may comprise corner fittings having lower orifices, wherein the spacer
comprises at least
one upward projection, and wherein providing the upper volumetric modules
above the
volumetric construction modules comprises mating the at least one upward
projection
with one of the lower orifices.
[0016] Each of the frames of the first and second volumetric construction
modules may
comprise a rectangular parallelpiped frame. The rectangular parallelpiped
frame may
comprise at least a part of a frame of an intermodal shipping container. The
curable
material may comprise concrete.
[0017] Another aspect of the invention provides a method of modular building
construction comprising: (a) providing first and second volumetric
construction modules
in lateral relation, each module comprising a frame, the frame comprising a
first segment;
(b) providing a panel expansion member spanning opposing top rails of the
frames and a
floor frame between opposing bottom rails of the frame, the space between the
panel
expansion member and the floor frame defining an expansion space, wherein at
least one
of the panel expansion member and the floor frame comprise a second segment;
(c)
defining a volume of a composite segment, the volume integrating the first
segment and
the second segment; and (d) filling the volume with a curable material to cast
the
composite segment. In step (c) the volume may contain at least a portion of
the first and
second segments. Step (c) may comprise defining a boundary of the volume with
temporary formwork. Step (c) may comprise defining at least a portion of the
boundary
of the volume with the first and second segments. The method may include,
prior to step
(d), a step (c)(i) comprising augmenting the structural capacity of the
composite segment.
Step (c)(i) may comprise coupling the first segment and/or the second segment
to a
plurality of shear connectors extending into the volume. Step (c)(i) may
comprise
providing a plurality of first and second reinforcement elements, the first
and second
reinforcement elements extending in transverse planes with respect to each
other. The
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first reinforcement elements may comprise rebar rods and the second
reinforcement
elements comprise rebar stirrups.
[0018] Each volumetric construction module may have an opening defined in its
side that
faces the expansion space, and wherein the volumes comprises a space between
the
modules and the expansion space adjacent the opening. The volume may comprise
a
space between adjacent corners of the frame of the at least one of the first
and second
volumetric construction modules. The volume may comprise a space adjacent an
edge of
the frame of at least one of the first and second volumetric construction
modules. A side
of the first volumetric construction module may be aligned with the side of
the second
volumetric construction module, with the expansion space located therebetween.
A side
of the first volumetric construction module may be aligned with an end of the
second
volumetric construction module, with the expansion space located therebetween.
An end
of the first volumetric construction module may be aligned with an end of the
second
volumetric construction module, with the expansion space located therebetween.
The
panel expansion member may partially define a bottom boundary of a slab volume
above
the modules and the expansion space. The panel expansion member may comprise a
structural member at two side regions of the panel expansion member wherein
spanning
opposing top rails comprises resting at least a portion of the structural
member on the top
rails. The structural member may comprise a hot or cold rolled steel section,
such as a
plate, I beam or truss. The structural member may be provided with upwardly
projecting
shear connectors. Each of the frames of the first and second volumetric
construction
modules may comprise a rectangular parallelpiped frame. The rectangular
parallelpiped
frame may comprise at least a part of a frame of an intermodal shipping
container. The
panel expansion member may comprise at least a part of a panel of an
intermodal
shipping container. The floor frame may comprise at least a part of a floor
frame of an
intermodal shipping container. The curable material may comprise concrete.
[0019] Another aspect of the invention provides a method of modular building
construction comprising: (a) providing a first volumetric construction module
comprising
a frame, the frame comprising a first segment; (b) providing a partially
constructed
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building comprising a frame comprising a second segment; (c) defining a volume
of a
composite segment, the volume integrating the first segment and the second
segment; and
(d) filling the volume with a curable material to cast the composite segment.
In step (c)
the volume may contain at least a portion of the first and second segments.
Step (c) may
comprise defining a boundary of the volume with temporary formwork. Step (c)
may
comprise defining at least a portion of the boundary of the volume with the
first and
second segments. Prior to step (d), a step (c)(i) may comprise augmenting the
structural
capacity of the composite segment. Step (c)(i) may comprise coupling the first
segment
and/or the second segment to a plurality of shear connectors extending into
the volume.
Step (c)(i) may further comprise providing a plurality of first and second
reinforcement
elements, the first and second reinforcement elements extending in transverse
planes with
respect to each other. The first reinforcement elements may comprise rebar
rods and the
second reinforcement elements may comprise rebar stirrups.
[0020] Another aspect of the invention provides a modular building diaphragm
comprising: roof panels of first and second volumetric construction modules in
laterally
adjacent relation; floor frames of third and fourth volumetric construction
modules in
laterally adjacent relation, the third and fourth modules above the first and
second
modules, respectively; a beam soffit member connected between upper portions
of the
first and second modules and having one or more shear connectors extending
upwardly
between the third and fourth modules; and a continuous body of concrete in
contact with
at least a portion of each of the roof panels of the first and second modules,
the laterally
adjacent portions of the third and fourth modules, and the beam soffit member,
the
concrete bonded in composite action with the one or more shear connectors of
the beam
soffit member.
[0021] Another aspect of the invention provides a modular building diaphragm
comprising: roof panels of first and second volumetric construction modules in
laterally
adjacent relation; floor frames of third and fourth volumetric construction
modules in
laterally adjacent relation, the third and fourth modules above the first and
second
modules and, respectively, bottom rails of the third and fourth modules
rigidly connected
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by at least one shear connector; a structural member connected between upper
portions of
the first and second modules; and at least one first reinforcing element
extending in a
direction parallel to a long axis of the bottom rails; a plurality of second
reinforcing
elements oriented in a plane transverse to the long axis of the bottom rails,
each of the
second reinforcing elements coupling the at least one shear connector to the
at least one
first reinforcing element; and a continuous body of concrete in contact with
at least a
portion of each of the roof panels of the first and second modules, the
laterally adjacent
portions of the third and fourth modules, the at least one first reinforcing
element, the
plurality of second reinforcing elements, and the structural member, the
concrete bonded
in composite action with the one or more shear connectors of the beam soffit
member.
[0022] Another aspect of the invention provides a column in a modular
building, the
column comprising: a first panel section of a first volumetric construction
module; a
second panel section of a second volumetric construction module, the second
panel
section parallel to and spaced apart from the first panel section; at least
one shear
connector extending into a volume between the first panel section and the
second panel
section and attached to at least one of the first panel section and the second
panel section;
at least one column closure member closing lateral sides of the volume between
the first
panel section and the second panel section; and concrete in the volume bonded
in
composite action with the at least one shear connector. The first module may
have an
opening defined in part by an inward edge of the first panel section, wherein
the second
module has an opening defined in part by an inward edge of the second panel
section, and
wherein the at least one column closure member borders the openings in the
first and
second modules. At least one shear connector may be attached to the at least
more
column closure member, wherein the concrete is bonded in composite action with
the at
least one shear connector attached to the at least one column closure member.
[0023] Another aspect of the invention provides a column in a modular
building, the
column comprising: a first corner post section of a first volumetric
construction module;
a first vertically extending reinforcement member; a first plurality of shear
connectors
rigidly connecting the first corner post section to the first vertically
extending
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reinforcement member; a volume defined by temporary formwork, the volume
surrounding and including the first corner post section, the first vertically
extending
reinforcement member, and the first plurality of shear connectors; and
concrete in the
volume encasing and bonding in composite action the first corner post section,
the first
vertically extending reinforcement member, and the first plurality of shear
connectors.
The column may further comprise a second corner post section of a second
volumetric
construction module adjacent the first corner post section; a second
vertically extending
reinforcement member; a second plurality of shear connectors rigidly
connecting the
second corner post section to the second vertically extending reinforcement
member;
wherein the volume additionally surrounds and includes the second corner post
section,
the second vertically extending reinforcement member, and the second plurality
of shear
connectors; and wherein the concrete in the volume additionally encases and
bonds in
composite action the second corner post section, the second vertically
extending
reinforcement member, and the second plurality of shear connectors.
[0024] Another aspect of the invention provides a column in a modular
building, the
column comprising: a first corner post section of a first volumetric
construction module;
a second corner post section of a second volumetric construction module
adjacent the
first corner post section; a first plurality of shear connectors rigidly
connecting the first
corner post section to the second corner post section; a volume defined by
temporary
formwork, the volume surrounding and including the first corner post section,
the second
corner post section, and the first plurality of shear connectors; and concrete
in the volume
encasing and bonding in composite action the first corner post section, the
second corner
post section, and the first plurality of shear connectors. The column may
further
comprise a third corner post section of a third volumetric construction module
adjacent
the first or second corner post section; a fourth corner post section of a
forth volumetric
construction module adjacent the third corner post section; a second plurality
of shear
connectors rigidly connecting the third corner post section to the fourth
corner post
section; wherein the volume additionally surrounds and includes the third
corner post
section, the fourth corner post section, and the second plurality of shear
connectors; and
wherein the concrete in the volume additionally encases and bonds in composite
action
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the third corner post section, the fourth corner post section, and the second
plurality of
shear connectors.
[0025] Another aspect of the invention provides a column in a modular
building, the
column comprising: a first corner post section of a first volumetric
construction module;
at least one first reinforcing element extending in a direction parallel to a
long axis of the
first corner post section; at plurality of second reinforcing elements
oriented in a plane
transverse to the long axis of the first corner post section, each of the
second reinforcing
elements surrounding both the first corner post section and the at least one
first
reinforcing element; and a volume defined by temporary formwork, the volume
surrounding and including the first corner post section, the at least one
first reinforcing
element and the plurality of second reinforcing elements; and concrete in the
volume
encasing and bonding in composite action the first corner post section, the at
least one
first reinforcing element and the plurality of second reinforcing elements.
The column
may further comprise a second corner post section adjacent the first corner
post section,
wherein each of the second reinforcing elements surround the second corner
post section,
wherein the volume surrounds and includes the second corner post section, and
wherein
the concrete in the volume encases and bonds in composite action the first
corner post
section, the second corner post section, the at least one first reinforcing
element and the
plurality of second reinforcing elements. The at least one first reinforcing
element may
comprise a rebar rod, and the plurality of second reinforcing elements
comprise rebar
stirrups.
[0026] Another aspect of the invention provides a beam in a modular building,
the beam
comprising: a first horizontal rail of a first volumetric construction module;
a second
horizontal rail of a second volumetric construction module, the second
horizontal rail
parallel to and spaced apart from the first rail; at least one shear connector
extending into
a volume between the first rail and the second rail and attached to at least
one of the first
rail and the second rail; a beam soffit member below the first rail and the
second rail, the
beam soffit member having one or more shear connectors extending into the
volume
between the first rail and the second rail; and concrete in the volume between
the first rail
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and the second rail, the concrete bonded in composite action with the at least
one shear
connector attached to at least one of the first rail and the second rail and
with the one or
more shear connectors of the beam soffit member. The first module may have an
opening
defined above the first rail, wherein the second module has an opening defined
above the
second rail, and wherein an upper face of the concrete borders the openings in
the first
and second modules.
[0027] Another aspect of the invention provides a beam in a modular building,
the beam
comprising: a first horizontal rail of a first volumetric construction module;
a second
horizontal rail of a second volumetric construction module, the second
horizontal rail
parallel to and spaced apart from the first rail; at least one shear connector
extending
between the first rail and the second rail and attached to at least one of the
first rail and
the second rail; at least one first reinforcing element extending in a
direction parallel to a
long axis of the first and second horizontal rail; at plurality of second
reinforcing
elements oriented in a plane transverse to the long axis of the first and
second horizontal
rail, each of the second reinforcing elements coupling the at least one shear
connector to
the at least one first reinforcing element; and a structural member below the
first rail, the
second rail, the at least one first reinforcing element, and the plurality of
second
reinforcing elements; and concrete in a volume defined between the first rail
and the
second rail, the concrete bonded in composite action with the at least one
shear
connector, the at least one first reinforcing element, and the plurality of
second
reinforcing elements. The structural member may be comprise a hot or cold
rolled steel
section, such as a plate, I beam or truss. The plurality of second reinforcing
elements
may be substantially U-shaped, wherein end regions of the U-shape engage the
at least
one shear connector, and a middle region of the U-shape engages the at least
one first
reinforcing element. The at least one first reinforcing element may comprise a
rebar rod,
and the plurality of second reinforcing elements comprise rebar stirrups.
[0028] Another aspect of the invention provides a shear wall in a modular
building, the
shear wall comprising: a shear wall panel; at least a portion of one end or
side of a
volumetric construction module; at least one connector rigidly fixed to and
extending
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between the shear wall panel and the portion of the one end or side; concrete
in a volume
defined between the shear wall panel and the portion of one end or side. The
shear wall
panel may comprise repurposed intermodal shipping container wall material.
[0029] Another aspect of the invention provides a volumetric construction
module
comprising: a frame having opposed ends and opposed sides extending between
the ends;
and one or more shear connectors projecting outwardly from the frame. The
frame may
comprise at least part of a rectangular parallelepiped frame of an intermodal
shipping
container. The one or more shear connectors may extend between adjacent
corners of the
frame. The one or more shear connectors may comprise an array of stud-type
shear
connectors. The one or more shear connectors may comprise at least one strip-
type shear
connector. The one or more shear connectors may be located adjacent an edge of
the
frame. The edge may comprise an edge between one of the ends of the frame and
one of
the sides of the frame. The frame may comprise a plurality of vertical posts,
and wherein
at least one of the one or more shear connectors is attached to one of the
posts. The
module may comprise a panel section coupled to the frame, wherein at least one
of the
one or more shear connectors is attached to the panel section. The edge may
comprise an
edge between a bottom of the frame and one of the sides of the frame. The edge
may be
located along the top of one of the ends. The frame may comprise a horizontal
rail, and
at least one of the one or more shear connectors may be attached to the rail.
The frame
may have an opening in one of its sides, wherein at least one of the shear
connectors
extends along an edge of the opening.
[0030] Another aspect of the invention provides a method for making a
volumetric
construction module, the method comprising: providing an intermodal shipping
container; installing one or more shear connectors on the outside of the
container. The
method may comprise removing a portion of a side panel of the container to
define an
opening in a side of the container. The method may comprise detachably
fastening the
removed portion of the side panel to the container. Installing the one or more
shear
connectors may comprise: attaching the one or more shear connectors to the
removed
portion of the side panel; and laminating the removed portion of the side
panel to a
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remaining portion of the side panel of the container. Installing the one or
more shear
connectors may comprise installing one or more shear connectors between
adjacent
corners of the container. Installing the one or more shear connectors may
comprise
installing an array of stud-type shear connectors. Installing the one or more
shear
connectors may comprise installing at least one strip-type shear connector.
Installing the
one or more shear connectors may comprise installing the one or more shear
connectors
adjacent to an edge of the container. The edge may comprise an edge between an
end of
the container and a side of the container. Installing the one or more shear
connectors may
comprise attaching at least one of the one or more shear connectors to a post
of the
container. Installing the one or more shear connectors may comprise attaching
at least
one of the one or more shear connectors to a panel of the container. The edge
may
comprise an edge between a bottom of the container and a side of the
container. The edge
may comprise an edge between a top of the container and an end of the
container.
Installing the one or more shear connectors may comprise attaching at least
one of the
one or more shear connectors to a horizontal rail of the container. Installing
the one or
more shear connectors may comprise welding at least one of the one or more
shear
connectors to the container. Installing the one or more shear connectors may
comprise
adhesively bonding at least one of the one or more shear connectors to the
container.
Installing the one or more shear connectors may comprise mechanically coupling
at least
one of the one or more shear connectors to the container.
[0031] Another aspect of the invention provides a building comprising: two
volumetric
construction modules in adjacent relation, each module comprising: a frame
having
opposed ends and opposed sides extending between the ends, and one or more
first shear
connectors coupled to the frame and extending toward the other module; at
least one first
closure member closing lateral sides of a first volume between the modules
that includes
the one or more first shear connectors; and concrete occupying the first
volume. Each
module may have an opening defined in its side that faces the other module,
and wherein
the first volume is adjacent the openings. Each of the modules may comprise
one or
more second shear connectors, and wherein the building comprises: at least one
second
first closure member closing lateral sides of a second volume between the
modules that
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includes the one or more second shear connectors; and concrete occupying the
second
volume, wherein the second volume is spaced apart from the first volume and
adjacent
the openings in the modules. The frame of each module may comprise at least
part of a
rectangular parallelpiped frame of an intermodal shipping container.
[0032] Another aspect of the invention provides a building comprising: a first
volumetric
construction module comprising a frame, the frame comprising a first segment;
a volume
of a composite segment, the volume integrating the first segment; and concrete
occupying
the volume. The building may comprise a structure adjacent the first
volumetric
construction module, the adjacent structure comprising a second segment,
wherein the
volume integrates the first segment and the second segment. The adjacent
structure may
comprise a second volumetric construction module, an expansion space, and/or a
partially
constructed building. The volume may contain at least a portion of the first
and second
segments, wherein boundaries of the volume are formed by temporary formwork.
The
building may comprise a base isolation system.
[0033] In addition to the exemplary aspects and embodiments described above,
further
aspects and embodiments will become apparent by reference to the drawings and
by
study of the following detailed descriptions.
Brief Description of Drawings
[0034] The accompanying drawings show non-limiting example embodiments.
[0035] Figure 3 is an isometric view of a volumetric construction module
according to an
example embodiment.
[0036] Figure 3A is an isometric view of a volumetric construction module
according to
an example embodiment.
[0037] Figure 4 is an isometric view of panel sections of the volumetric
construction
module of Figure 3.
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[0038] Figure 4A is a detail isometric view of an angle member installed on a
panel
section shown in Figure 4.
[0039] Figure 5 is a side elevation view of the volumetric construction module
of Figure
3.
[0040] Figure 6 is a top plan view of the top of the volumetric construction
module of
Figure 3.
[0041] Figure 7A is an opening end elevation view of the volumetric
construction
module of Figure 3.
[0042] Figure 7B is a closed end elevation view of the volumetric construction
module of
Figure 3.
[0043] Figure 8A is an isometric view of a column closure member according to
an
example embodiment.
[0044] Figure 8B is an isometric view of a column closure member according to
another
example embodiment.
[0045] Figure 8C is an isometric view of a column reinforcement member
according to
an example embodiment.
[0046] Figure 9 is an isometric view of a beam soffit member according to an
example
embodiment.
[0047] Figure 9A is an isometric view of a panel expansion member according to
an
example embodiment.
[0048] Figure 10 is an isometric view of a spacer according to an example
embodiment.
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[0049] Figure 11 is an isometric view of a slab edge form member according to
an
example embodiment.
[0050] Figure 12 is an isometric view of an assembly according to an example
embodiment comprising the volumetric construction module of Figure 3, the
members of
Figures 8A, 8B and 9, the spacer of Figure 10 and the edge form member of
Figure 11.
[0051] Figure 13 is a flow chart of a construction method according to an
example
embodiment.
[0052] Figure 14 is an isometric view of an assembly illustrating stages of
construction
according to an example implementation of the method of Figure 13.
[0053] Figure 15 is a detail isometric view of a corner of four adjacent
modules
assembled according to an example implementation of the method shown in Figure
13.
[0054] Figure 16 is a cross-section through a composite beam according to an
example
embodiment.
[0055] Figure 17 is a cross-section through a composite beam according to
another
example embodiment.
[0056] Figure 18 is a cross-section through a composite beam according to a
further
example embodiment.
[0057] Figure 19 is a cross-section through a composite beam according to a
further
example embodiment.
[0058] Figure 20 is a cross-section through a composite beam according to a
further
example embodiment.
[0059] Figure 21 is an isometric view of a spacer according to an example
embodiment.
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[0060] Figure 22 is an isometric view of an assembly according to an example
embodiment comprising the volumetric construction module of Figure 3, the
members of
Figures 8B and 9, and the spacer of Figure 21.
[0061] Figure 23 is a flow chart of a construction method according to an
example
embodiment.
[0062] Figure 24 is an isometric view of an assembly illustrating stages of
construction
according to an example implementation of the method of Figure 23.
[0063] Figure 24A is a close up isometric view of a portion of the assembly of
Figure 24.
[0064] Figure 25 is an end view cross-section of a portion of the assembly of
Figure 24.
[0065] Figure 26 is a cross-section through a composite beam according to a
further
example embodiment.
[0066] Figure 27 is a cross-section through a composite beam according to a
further
example embodiment.
[0067] Figure 27A is a detail isometric view of a corner of four adjacent
modules
assembled according to an example implementation of the method shown in Figure
23.
[0068] Figure 28 is an isometric view of a multi-story building according to
an example
embodiment.
[0069] Figure 29 is a floor plan of the building shown in Figure 28, shown
with modules
removed.
[0070] Figure 30 is a floor plan of the building shown in Figure 28 with
modules shown.
[0071] Figure 31 is a side elevation view of the building core of the building
shown in
Figure 28.
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[0072] Figure 32 is a schematic plan view cross-section through a column
formed in part
by four corner adjacent opening end corner posts.
[0073] Figure 33 is a schematic plan view cross-section through a column
formed in part
by four corner adjacent closed end corner posts.
[0074] Figure 34 is a schematic plan view cross-section through a column
formed in part
by two laterally adjacent closed end corner posts.
[0075] Figure 35 is a schematic plan view cross-section through a column
formed in part
by two facing adjacent opening end corner posts.
[0076] Figure 36 is a schematic plan view cross-section through a column
formed in part
by two laterally adjacent opening end corner posts.
[0077] Figure 37 is a schematic plan view cross-section through a column
formed in part
by one opening end corner post.
[0078] Figure 38 is a schematic plan view cross-section through a column
formed in part
by four corner adjacent opening end corner posts.
[0079] Figure 39 is a schematic plan view cross-section through a column
formed in part
by two corner adjacent facing closed end corner posts.
[0080] Figure 40 is a schematic plan view cross-section through a column
formed in part
by one closed end corner post.
[0081] Figure 41 is a schematic plan view cross-section through a shear wall
according to
an example embodiment.
[0082] Figure 42 is a schematic plan view cross-section through a column
formed in part
by two facing adjacent opening end corner posts according to an example
embodiment.
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[0083] Figure 43 is a schematic plan view cross-section through a column
formed in part
by an opening end corner posts according to an example embodiment.
[0084] Figures 44 and 44A are isometric and cross section views, respectively,
through a
composite beam according to an example embodiment.
[0085] Figure 45 is a cross section through a composite beam according to an
example
embodiment.
[0086] Figure 46 is a cross section through a composite beam according to an
example
embodiment.
[0087] Figure 47 is a cross section through a composite beam according to an
example
embodiment.
Description
[0088] Throughout the following description specific details are set forth in
order to
provide a more thorough understanding to persons skilled in the art. However,
well
known elements may not have been shown or described in detail to avoid
unnecessarily
obscuring the disclosure. Accordingly, the description and drawings are to be
regarded in
an illustrative, rather than a restrictive, sense.
[0089] In some embodiments of the invention, volumetric construction modules
are
integrated with concrete and/or other curable materials having high-
compressive strength
to form composite segments (e.g., columns, beams, slabs, diaphragms, etc.
comprising
steel and concrete). In particular, in some embodiments, one or more segments
(e.g.
corner posts, end rails, side rails, etc.) of volumetric construction modules
may be
integrated with a curable material to form the composite segment. Shear
connections or
other means (e.g. fibre reinforced polymer wraps) may be provided in
particular
embodiments to augment the structural capacity of the composite segment while
in other
particular embodiments such augmentation is not provided (i.e., structural
capacity is
derived solely from the segments integrated with the high strength curable
material). For
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simplicity of exposition, a volumetric construction module and various
components
according to an example embodiment are introduced first, and this is followed
by an
explanation of how the module and components may be combined in a building
according to an example embodiment.
[0090] Volumetric construction modules according to some example embodiments
comprise at least some parts of intermodal shipping containers. Presently,
intermodal
shipping containers can be obtained in developed countries at relatively low
prices (in
some cases less than the cost of their component materials) due to global
trade
imbalances. Embodiments which comprise intermodal shipping containers may reap
cost
advantages from the availability of low-cost intermodal shipping containers.
Such
embodiments may also reap advantages associated with ease of transporting
these
containers, as well as with the standard dimensions, tight tolerances and
specified
structural capacities to which these containers are built. In some
embodiments, the
volumetric construction module may comprise other suitable modules including
purpose
built modules. The shape of the volumetric construction module may be
rectangular or
any other shape suitable for the particular application.
[0091] Figure 1 is an isometric view of an intermodal shipping container 10.
Figure 2 is a
partially-exploded isometric view of container 10. Container 10 comprises an
International Standards Organization (ISO) high cube 20 foot container.
Container 10 is
6058 mm (19 feet 10 1/2 inches) long, 2438mm (8 feet) wide and 2896 mm (9 feet
6
inches) high. Container 10 is made from weathering steel (e.g., COR-TEN
weathering
steel).
[0092] Container 10 comprises a volumetric parallelepiped frame 12. Frame 12
comprises a rectangular opening end frame 22 at its opening end 20, a
rectangular closed
end frame 32 at its closed end 30, and rectangular side frames 42L and 42R at
its left and
right sides 40L and 40R, respectively. Side frames 42L and 42R may be referred
to
collectively or generally herein as side frames 42. The terms "opening end"
and "closed
end" are used herein to denote the different ends of example containers and
shipping
modules for convenience only, and it will be understood that different
container and
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modules not having opening and closed ends may be used in embodiments of the
invention.
[0093] Opening end frame 22 comprises a top opening end rail 24, bottom
opening end
rail 26, left opening end corner post 28L and right opening end corner post
28R. Opening
end corner posts 28L and 28R may be referred to collectively or generally
herein as
corner posts 28. Closed end frame 32 comprises a top closed end rail 34,
bottom closed
end rail 36, left closed end corner post 38L (not shown in Figure 1; see
Figure 2) and
right closed end corner post 38R. Closed end corner posts 38L and 38R may be
referred
to collectively or generally herein as corner posts 38.
[0094] Corner fittings 14 are located at each of the corners of opening end
frame 20 and
closed end frame 30. Corner fittings 14 have orifices 16 on their exposed
faces for
connecting, lifting and lashing container 10 during transport and handling.
Side rails
extend between opposite corner fittings 14 of opening end frame 22 and closed
end frame
32. More particularly:
= top left side rail 44L extends between corner fitting 14 at the top left
corner of
opening end frame 22 and corner fitting 14 at the top left corner of closed
end
frame 32;
= top right side rail 44R extends between corner fitting 14 at the top
right corner of
opening end frame 22 and corner fitting 14 at the top right corner of closed
end
frame 32;
= bottom left side rail 46L (not shown in Figure 1; see Figure 2) extends
between
corner fitting 14 at the bottom left corner of opening end frame 22 and corner
fitting 14 at the bottom left corner of closed end frame 32; and
= bottom right side rail 46R extends between corner fitting 14 at the
bottom right
corner of opening end frame 22 and corner fitting 14 at the bottom right
corner of
closed end frame 32.
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[0095] Left side frame 42L comprises left opening corner post 28L, left closed
corner
post 38L, top left side rail 44L, and bottom left side rail 46L. Right side
frame 42R
comprises right opening corner post 28R, right closed corner post 38R, top
right side rail
44R, and bottom right side rail 46R. As described above, corner posts 28 and
38 are,
respectively, also components of opening and closing end frames 22 and 32. Top
side
rails 44L and 44R may be referred to collectively or generally herein as top
side rails 44.
Bottom side rails 46L and 46R may be referred to collectively or generally
herein as top
side rails 46.
[0096] End frames 22 and 32, and side frames 42 are closed by either
corrugated steel
panels or by doors in the case of opening end frame 22. Doors 52 hingedly
connected to
opening end corner posts 28 are pivotable to selectively close opening end
frame 22.
When closed, doors 52 span opening end corner posts 28, top opening end rail
24 and
bottom opening end rail 26. An end panel 54 closes closed end frame 32. A left
side
panel 56L closes left side frame 42L. A right side panel 56R closes right side
frame 42R.
The top face of container 10 is closed by a top panel 58.
[0097] The bottom of container 10 comprises a floor frame 62 comprising left
and right
bottom side rails 46L and 46R, opening end bottom rail 26 and a closed end
bottom rail
36 (not shown in Figure 1; see Figure 2). Floor frame 62 is spanned by spaced
transverse
joists 68. Floor joists 68 are coupled at their ends to bottom side rails 46.
A plywood
panel 70 above floor frame 62 is fastened to joists 68, bottom side rails 46,
opening
bottom rail 64, and closed bottom rail 66. Tubular forklift pockets 72
intermediate
bottom end rails 26 and 36 span bottom side rails 46.
[0098] Container 10 is designed and built to be loaded and stacked on
container ships. A
twenty foot ISO standard intermodal shipping container 10 has a tare weight of
2,220
kilograms (4,894 lbs.), can be loaded to a gross weight up to 30,480 kilograms
(67,197
= lbs.), and can be stacked 9 high (i.e., can support the weight of 8
loaded containers
weighing a total of 244 metric tonnes). In modern intermodal shipping
container designs
all components participate in the container's structural integrity, and the
specified level of
structural capability is assured only when all walls, floors and roofs are in
place and
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doors are closed. Removing any portion of an intermodal shipping container
(e.g., to
provide windows or doors, or to open up rooms), will compromise structural
integrity.
Since windows, doors, and open rooms are practical necessities for habitable
buildings,
construction of multi-story buildings from intermodal shipping containers
requires
additional support to carry vertical and lateral loads present in these
buildings.
[0099] Some parts of intermodal shipping containers are stronger than others.
For
example, floor frame 62 and corner posts 28 and 38 of container 10 are
relatively strong.
More particularly:
= floor frame 62 of container 10 comprises bottom side rails 46, which are
constructed of steel C-channel beams to withstand longitudinal tensile loads,
floor joists 68, which are constructed of steel C-channel beams to withstand
transverse tensile loads, and bottom end rails 26 and 36, which are
constructed of
steel box sections; and
= corner posts 28 and 38 are constructed from steel C-channel sections
closed with
welded steel plate.
[0100] Some embodiments of the invention provide volumetric construction
modules
adapted to integrate the relatively strong parts of container 10 into
composite structural
members (e.g., columns, beams, slabs and diaphragms). Example embodiments of
volumetric construction modules and buildings constructed therefrom using
containers
such as container 10 are described below. It is to be understood that the
features and
techniques disclosed herein could also be applied to other types of containers
or other
types of volumetric construction modules.
[0101] Figures 3, 4, 4A, 5, 6, 7A and 7B show a volumetric construction module
100, or
at least portions thereof, according to an example embodiment. More
particularly:
= Figure 3 is an isometric view of module 100;
= Figure 4 is an isometric view of panel sections of the module 100;
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= Figure 4A is a detail isometric view of an angle member installed on a
removable
panel section of module 100;
= Figure 5 is a side elevation view of module 100;
= Figure 6 is a top plan view of module 100;
= Figure 7A is an opening end elevation view of module 100; and
= Figure 7B is a closed end elevation view of module 100.
[0102] Module 100 comprises parts of an intermodal shipping container. Those
parts are
identified using the same reference numerals used to identify like parts of
container 10,
and are not described again here. Like container 10, module 100 is laterally
symmetric.
For convenience, laterally symmetric features of module 100 are described
generally with
reference to reference numbers indicating these features on the lateral side
of module 100
whose outward surface is visible in Figure 3 (which side corresponds to left
side 40L of
container 10). Modules according to some embodiments of the invention are not
laterally
symmetric.
[0103] Module 100 comprises frame 12. A first opening 22A is defined by
opening end
frame 22, which in container 10 was selectively closable with doors 52. A
second
opening 32A defined by closed end frame 32, which in container 10 was closed
by closed
panel 54.
[0104] Module 100 comprises opposed side openings 102. Openings 102 are
defined in
part by panel sections 128 and 138 located on the sides 40 of module 100
adjacent the
opening end 20 and closed end 30, respectively, of module 100. The top and
bottom
sides of panel sections 128 and 138 are attached, respectively, to top side
rail 44 and
bottom side rail 46. Panel section 128 is attached along one side to opening
end corner
post 28. Panel section 138 is attached along one side to closed end corner
post 38.
[0105] Openings 102 correspond to removable panel sections 104 shown in Figure
4.
Figure 4 shows the doors 52, end panel 54 and panel sections 104 removed from
an
intermodal shipping container to create openings 22A, 32A, and 102 of module
100. In
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some embodiments, one or more of doors 52, end panel 54 and panel sections 104
is
detachably fastened to module 100 to cover a corresponding opening in module
100, so
as to be optionally detachable before and/or after module 100 is used in
constructing a
building. Some non-limiting example uses of detachable doors, panels and panel
sections
include:
= protecting the interior of module 100 during pre-fabrication of internal
components of module 100 and/or transportation of module 100,
= providing selectable building configurations,
= acting as shoring or formwork during construction of buildings
incorporating
module 100,
= providing structural reinforcement to other panel sections of module 100
(e.g., by
laminating a detachable panel section onto another panel section coupled to
frame
12 by welding, heat bonding, adhesive, mechanical connection and/or other
suitable laminating techniques),
= using them as a slab soffit for a composite concrete slab extending between
container modules,
= and
= the like.
[0106] In Figure 4, panel sections 128 and 138 are shown positioned according
to their
locations on module 100 in order to illustrate how they and panel sections 104
may be
obtained from side panels 56 of a container 10.
[0107] Figure 4A is an isometric view of a portion of one of panel sections
104. Panel
sections 104 comprise lengths of steel angle 90 along their top edges 104T. A
vertical leg
of angle 90 is fastened along top edge 104T. A horizontal leg of angle 90
extends
perpendicular to panel section 104 and is generally aligned with top edge
104T. Angle 90
may be used for detachably fastening wall section 104 to top side rail 44,
such as by tack
welds, mechanical fasteners, or the like. Panel sections 104 also comprise
lengths of
steel angle 96 along their bottom edges 104B. Angle 96 is similar to angle 90
and may be
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used for fastening panel sections 104 to bottom side rails 46. In similar
fashion, closed
end panel 54 comprises lengths of steel angle (not specifically identified in
the Figures)
along its top and bottom edges, which may be used to fasten end panel 54 to
close
opening 54A of module 100. In some embodiments, module 100 comprises connector
components (e.g., lengths of steel angle, mechanical fastener components,
etc.) to
facilitate fastening of panel sections 104 and end panel 54 to module 100.
[0108] Module 100 comprises a plurality of shear connectors 110 coupled to
frame 12.
As described in further detail below, shear connectors 110 may facilitate
integration of
module 100 and components thereof into composite structural members. In the
illustrated
embodiment, arrangement of shear connectors 110 is laterally symmetric, but
this is not
necessary.
[0109] Sides 40 of module 100 comprises shear connector arrays 1120 and 112C.
Shear
connector arrays 1120 and 112C each extend between adjacent corners of frame
12.
Shear connector arrays 1120 and 112C are adjacent opening end 20 and closed
end 30,
respectively, of module 100. In the illustrated embodiment, shear connector
arrays 1120
and 112C comprise outwardly projecting shear connectors 110 arrayed on panel
sections
128 and 138, respectively. More particularly, arrays 1120 and 112C each
comprise a
plurality (3) of vertical columns of spaced apart, laterally-extending headed
steel shear
studs. In array 1120, the shear studs 110 of the outward vertical column are
rigidly
connected to opening end corner post 28, through panel section 128, and the
shear studs
110 of the inward vertical columns are rigidly connected to panel section 128.
Similarly,
in array 112C, the shear studs 110 of the outward vertical column are rigidly
connected to
closed end corner post 38, through panel section 138, and the shear studs 110
of the
inward vertical columns are rigidly connected to panel section 138.
[0110] Sides 40 of module 100 also comprise shear connector arrays 114. Each
shear
connector array 114 comprises outwardly projecting shear connectors 110
adjacent the
bottom of module 100. In the illustrated embodiment, each array 114 comprises
a single
row of spaced apart, laterally-extending headed steel shear studs. The shear
studs 110 of
arrays 114 are rigidly connected to bottom side rails 46.
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[0111] The angular section at the top face 50 of module 100 comprises a shear
connector
array 116. Shear connector array 116 comprises outwardly projecting shear
connectors
110 adjacent the top of opening end opening 22A. More particularly, array 116
comprises
a single row of spaced apart headed steel shear studs welded to the angular
portion. The
shear studs 110 of array 116 are rigidly connected to top opening end rail 24.
[0112] Opening end 20 of module 100 comprises a shear connector array 1180.
Shear
connector array 1180 comprises outwardly projecting shear connectors 110
adjacent the
bottom of first opening 22A. In the illustrated embodiment, array 1180
comprises a
single row of spaced apart headed steel shear studs. The shear studs 110 of
array 1180
are rigidly connected to opening end bottom rail 26. In some embodiments,
module 100
may not have shear connector array 1180 (e.g., in embodiments where opening
end 20 of
module 100 forms part of an outward face of a building).
[0113] Closed end 30 of module 100 comprises a shear connector array 118C.
Shear
connector array 118C comprises outwardly projecting shear connectors 110
adjacent the
bottom of second opening 32A. In the illustrated embodiment, array 118C
comprises a
single row of spaced apart headed steel shear studs. The shear studs 110 of
array 118C
are rigidly connected to closed end bottom rail 36. Shear connector arrays
1180 and
118C may be referred to interchangeably or collectively herein as shear
connector arrays
118.
[0114] Though shear connectors 100 in the illustrated embodiment comprise
headed steel
shear studs, in other embodiments any suitable type (or combination of types)
of shear
connectors may be provided. Non-limiting examples of other types of shear
connectors
that may be used in embodiments include:
= shear bolts;
= deformed bar anchors;
= ties, threaded rods or bolts fastened to opposing members with nuts;
= perforated, oscillated, waveform and profiled strips,
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= T connectors,
= HiltiTM HVB connectors;
= HambroTM top cord elements; and
= the like.
[0115] A row or column of shear connector arrays 1120, 112C, 114 116 and/or
118 may
comprise as few as one shear connector. For example, in some embodiments,
arrays
1120 and 112C each comprise three parallel, spaced apart, vertically-oriented
strip-type
shear connectors. In some embodiments, a few as one shear connector may extend
between adjacent corners of frame 12. For example, array 114, 116 and/or array
118 may
comprise a single strip-type shear connector that extends between adjacent
corners of
frame 12. Though arrays 1120, 112C, 114, 116 and 118 of the illustrated
embodiment
comprise rectangular arrays, this is not necessary. Arrays of shear connectors
need not
exhibit regular spacing between adjacent shear connectors, and may comprise
rows
and/or columns having different numbers of (and different types of) shear
connectors.
Arrays of shear connectors may exhibit other geometric patterns, such as
triangles,
diamonds, arcs, circles and the like, for example.
[0116] In some embodiments, at least some shear connectors are arranged on
module 100
to be staggered with respect to counterpart shear connectors located on an
opposite side
or end of module 100. This may enable shear connectors of laterally adjacent
modules
100 to pass each other in overlapping fashion when the modules 100 are placed
in close
laterally adjacent relation.
[0117] As will become more apparent from the discussion below, the type,
dimensions
arrangement, and spacing of shear connectors may be selected to provide a
desired degree
of composite action between module 100 and a curable material integrated with
the shear
connectors. In some embodiments, shear connectors may be located in different
locations
than in the example embodiment illustrated by module 100. For example, one or
more
structural members of module 100 that have shear connectors attached to them
may not
have shear connectors attached to them in other embodiments. In some
embodiments,
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shear connectors may be attached to structural members of a volumetric
construction
module that do not have shear connectors in module 100 (e.g., adjacent the top
of closed
end opening 32A, across top panel 58, on joists 68, etc.).
[0118] Shear connectors 110 may be rigidly connected to parts of module 100
using any
suitable type of connection, such as welding, mechanical connection (e.g.,
captive
threaded, nut-retained threaded, riveted, interlocking tab and slot, twist-
lock, etc.),
adhesive, heat bonding, or the like, for example. In some embodiments, shear
connectors
110 may be configured to be installed on module 100 on-site. For example,
structural
members of module 100 (such as corner posts 28 and 38, and bottom side rails
46, for
example) may comprise mechanical fastener components (e.g., holes, threaded
apertures,
slots, etc.) configured to mate with cooperating fastener components provided
on shear
connectors 110 (e.g., matched studs, threaded studs, notched tabs, etc.). In a
particular
example embodiment, shear connectors 110 comprise Nelson weld studs
manufactured
by Nelson Stud Welding, and may be installed by a drawn arc stud welding
process, such
as with a Nelson Ferrule Shooter.
[0119] Figure 3A is an isometric view of module 100' according to an example
embodiment. Module 100' is similar to module 100 except that shear connector
arrays
1120', 112C', 114', 116', and 118C' comprises shear bolts instead of headed
studs, shear
connector arrays 1120' and 112C' each comprise a single column of shear
connectors
instead of three columns of shear connectors, and each row of shear connector
arrays
114', 116', and 118C' comprises fewer numbers of shear connectors. Note in
Figure 3A
that the corner post has been cut from the side panel leaving a portion of the
heavier
gauge cold rolled C shape member on the exterior of the hot rolled C channel
making up
the corner post, i.e. the corner post has been cut off to improve the aspect
ratio of the
column and because it would otherwise add considerable concrete volume to the
column
with low steel content. The heavier gauge strip of steel from the corner post
may be left
on the corrugated side panel to add rigidity to the panel in a reuse function,
such as the
expansion panel member described further below.
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[0120] Some embodiments of the invention comprise one or more components that
facilitate the interconnection of modules 100, the integration of modules 100
into
composite structural members, and/or the creation of a volumetric space
between laterally
aligned modules 100. Figures 8A, 8B, 8C, 9, 9A, 10 and 11 show non-limiting
examples
of such components.
[0121] Figure 8A, 8B and 8C are isometric views of column closure members 150
and
160 and column reinforcement member 165 according to example embodiments. As
described in further detail below, members 150, 160 and 165 may be used to
provide a
structural connection between adjacent modules, and as part of an encasement
for a
composite structural column integrated with modules 100 and to strengthen the
column.
The cross-section of steel in the enclosure members may vary to meet the
demand of the
specific column. Column closure member 150 comprises a steel C channel 152
having a
plurality of shear connectors 154 projecting from the base of the channel 152.
Column
closure member 160 comprises a steel C channel 162 having a plurality of shear
connectors 164 projecting opposite the flange of channel 162. Column
reinforcement
member 165 comprises a steel C channel 167 having a plurality of holes 169
arranged in
the web of channel 167 to receive shear connectors of the modules or other
components.
[0122] Column closure member 160 comprises a steel C channel section 162
having a
plurality of shear connectors 164 projecting opposite the web of channel
section 162.
Shear connectors 164 may be arranged on channel section 162 so that shear
connectors
164 of closure member 160 are staggered with respect to those of an inverted
closure
member 160. This may enable shear connectors 164 of closure members 160 having
complementary orientations (i.e., one inverted, one not inverted) to pass each
other in
overlapping fashion when the closure members 160 are placed in close
opposition.
[0123] Figure 9 is an isometric view of a beam soffit member 170 according to
an
example embodiment. As described in further detail below, beam soffit member
170 may
be used to limit the deflection of the bottom side rail 46 of column 100, to
provide a
structural connection between adjacent modules 100, and to integrate modules
the floor
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frames of modules 100 into a structural diaphragm. Member 170 comprises a
steel plate
172 having a plurality of shear connectors 174 projecting from a major side
thereof.
[0124] Figure 9A is an isometric view of a panel expansion member 175
according to an
example embodiment. As described in further detail below, panel expansion
members
may be used to create an expansion space between laterally aligned modules
100. Panel
expansion member 175 comprises a pair of beam soffit members 170 coupled to
opposite
end regions of a panel member 177. Shear connectors 174 of beam soffit members
170
may project through corresponding holes in panel member 177 or the shear studs
may be
welded through the panel members to the beam soffit members with special
ferrules as
manufactured by Nelson Stud WeldingTM. Panel member 177 may for example
comprise
corrugated side wall steel of an intermodal shipping container.
[0125] Figure 10 is an isometric view of a spacer 180 according to an example
embodiment. As explained in further detail below, spacer 180 may be used to
align and
space vertically and laterally adjacent modules 100 in buildings according to
example
embodiments. Spacer 180 comprises a steel box section 182 closed on five
sides,
including end side 182E. Spacer 180 comprises a first pair of projections 184A
and 184B
on a top side 182T of box section 182 that are opposite a second pair of
projections 184C
and 184D on a bottom side 182B of box section 182. In the illustrated
embodiment,
projections 184 are configured to be received in the orifices 16 of corner
fittings 14 of
ISO standard intermodal shipping containers. A shear connector array 188
extends
upwardly from box section 182 between projections 184A and 184B. Shear
connectors
188A and 188B also extend from opposite ends of box section 182.
[0126] In the illustrated embodiments, shear connectors of column closures 150
and 160,
diaphragm anchoring plate 170 and spacer 180 comprise headed steel shear
studs, but any
other suitable type (or combination of types) of shear connector may be used
instead of or
in addition to headed steel shear studs.
[0127] Figure 11 is an isometric view of a slab edge form member 190 according
to an
example embodiment. As described in further detail below, slab edge form
member 190
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may be used as a form for an edge of a slab of curable material (e.g.,
concrete). Form
member 190 comprises a length of angle steel 192. A vertical leg 192V of angle
steel 192
is folded at its top edge 192T toward horizontal leg 192H to form an inclined
flap 194.
Member 190 comprises a strap 196 attached to flap 194 and extending downwardly
to a
foot 198. An aperture 196A is defined through strap 196 and flap 194. Foot 198
is
parallel to and spaced apart from horizontal leg 192H. An aperture 198A is
defined
through foot 198.
[0128] Figure 12 is an isometric view of an assembly 200 according to an
example
embodiment. Assembly 200 partially defines a plurality of volumes into which
curable
material (e.g., concrete) may be introduced to form composite structural
members (e.g.,
beams, columns, slabs, etc.). Assembly 200 comprises:
= volumetric construction module 100;
= a plurality of column closure members 150 and 160 (individually
identified in
Figure 12 as column closure members 1500, 150C, 1600 and 160C);
= abeam soffit member 170;
= a plurality of spacers 180 (individually identified in Figure 12 as
spacers 1800
and 180C); and
= a plurality of slab edge form members 190 (individually identified in
Figure 12 as
slab edge form members 1900 and 190C).
[0129] For convenience, features of the aforementioned components are
identified using
the same reference numerals as in their descriptions.
[0130] In assembly 200, column closure members 1500 and 1600 are generally
perpendicular to and abut opposite edges of panel section 128 to close
vertically-
extending sides of opening end column volume 228. In like fashion column
closure
members 150C and 160C are generally perpendicular to and abut opposite edges
of panel
section 138 to close vertically-extending sides of closed end column volume
238. As
described in further detail below, the open vertically-extending sides of
column volumes
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228 and 238 (opposite panel sections 128 and 138, respectively) may be closed
by an
adjacent volumetric construction module or another column closure member, so
that
column volumes 228 and 238 are laterally enclosed.
[0131] Column closure members 1600 and 160C also close vertically-extending
front
and rear ends, respectively of a beam volume 246. One vertically-extending
side of beam
volume 260 is closed by bottom side rail 46. As described in further detail
below, the
other vertically-extending side of beam volume 246 (opposite bottom side rail
46) may be
partially closed by an adjacent volumetric construction module or another beam
closure
member, so that beam volume 246 is laterally enclosed.
[0132] Opening end slab edge form member 1900 and opening end spacer 1800 form
a
wall that closes the vertically-extending side of slab volume 260 below
opening end 20 of
module 100. Closed end slab edge form member 190C and closed end spacer 180C
and
form a wall that closes the vertically-extending side of slab volume 260 below
closed end
30 of module 100. One projection (not visible in Figure 11) of each of spacers
1800 and
180C is engaged with a corresponding orifice 16 of one of corner fittings 14.
As
described in further detail below, the unengaged projections of spacers 1800
and 180C
may be mated with the orifices of the corner fittings 14 of other modules,
such as a
module below module 100 whose roof closes the bottom of slab volume 260, for
example.
[0133] Beam soffit member 170 is below and spaced apart from bottom side rail
46 and
closes a portion of the bottom side of a slab volume 260. More particularly,
plate 172 of
beam soffit member 170 is level with the bottoms of spacers 1800 and 180C. The
ends of
beam soffit member 170 are aligned with column closure members 1500 and 150C.
Shear connectors 174 of beam soffit member 170 extend through slab volume 260
into
beam volume 246.
[0134] It may be observed from Figure 12 that each of column volumes 228 and
238 is
closed on at least three vertically-extending sides by steel plate having
shear connectors
projecting into the volumes. In particular:
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= column volume 228 is closed on:
o a first side by C-channel beam 162 of column closure member 1600 and
includes shear connectors 164 that project therefrom,
o a second side by C-channel beam 152 of column closure member 1500
and includes shear connectors 154 that project therefrom, and
o a third side by panel section 128 and includes shear connectors 110 of
array 1120 that project therefrom; and
= column volume 238 is closed on:
o a first side by C-channel beam 152 of column closure member 150C and
includes shear connectors 152 that project therefrom,
o a second side by C-channel beam 162 of column closure member 160C
and includes shear connectors 164 that project therefrom, and
o a third side by panel section 138 and includes shear connectors 110 of
array 112C that project therefrom.
[0135] When the vertically extending outward sides of column volumes 228 and
238 are
closed by posts and/or panels of a laterally adjacent module and/or other
closure
members, all vertically-extending sides of each of column volumes 228 and 238
are
closed and the volumes are accordingly laterally enclosed.
[0136] It may also be observed from Figure 12 that column volumes 228 and 238,
beam
volume 246 and slab volume 260 are all continuous with each other, and that
neighbouring ones of these volumes include shear connectors rigidly connected
to the
same structural member. In particular:
= shear connectors 110 of shear connector array 114 on bottom side rail 46
project
into column volumes 228 and 238 and beam volume 246;
= spacers 1800 and 180R have shear connectors 186 that project into column
volumes 228 and 238 and shear connectors 188 that project into slab volume
260;
and
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= shear connectors 174 of beam soffit member 170 extend through slab volume
260
into beam volume 246.
[0137] Figure 13 is a flow chart of a construction method 300 according to an
example
embodiment. Figure 14 is an isometric view of an assembly 400 of four
volumetric
construction modules 100 (individually identified in Figure 14 as 400A, 400B,
400C and
400D) illustrating stages of construction according to an example
implementation of
method 300. Modules 400A, 400B and 400C are part of a first floor and module
400D is
located on top of module 400A as part of a second floor. Figure 14 shows
concrete
poured after installation of a fifth module 100 on top of module 400B and
adjacent to
module 400D; the fifth module is not shown in order to expose features of
assembly 400
that would otherwise be obscured. Modules 400A, 400B, 400C and 400D are shown
without doors 52, closed panels 54 and detachable sections 104 in Figure 14 to
avoid
obscuring features of assembly 400. In some embodiments, one or more of these
components is left in place at one or more of the illustrated stages of
construction (e.g.,
for hoarding and/or shoring until concrete has cured, for permanently dividing
adjacent
modules, for providing exterior walls, etc.).
[0138] Step 302 of method 300 comprises enclosing a slab volume. A slab volume
enclosed in step 302 may be defined in part by the roofs of the volumetric
construction
modules (e.g., volumetric construction module 100), for example. Or the slab
soffit may
be enclosed by a repurposed corrugated panel from the wall of a shipping
container. In
the illustrated embodiment, step 302 comprises enclosing a slab volume defined
in part
by the roofs of volumetric construction modules in spaced laterally adjacent
relation, and
includes steps 304 and 306.
101391 Step 304 comprises enclosing lateral sides of the slab volume.
Enclosing lateral
sides of a slab volume may comprise installing spacers 180 and slab edge
closures 190
above the top rails of a single module, or above the perimeter top rails of a
plurality of
adjacent modules, for example. Figure 14 shows an example of this in slab
volume 460
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which is partially laterally enclosed by slab edge closures 190D, which are
installed along
the top opening end rail, top side rail and top closed end rail of module
400D, and spacers
180D, which are installed into the adjacent top orifices of corner fittings of
module 400D.
Slab volume 460D includes shear connector array 116 located along top opening
end rail
of module 400D.
[0140] Step 306 comprises enclosing the space between upper portions of the
adjacent
sides of laterally adjacent modules. Figure 14 shows one example of step 306
in beam
soffit member 470, which is installed atop top side rails 44 of modules 400C
and 400B to
enclose the space between upper portions of the adjacent sides of modules 400B
and
400C.
[0141] Step 308 comprises introducing curable material, such as concrete, for
example,
to the slab volume enclosed in step 302. Figure 14 shows an example of this in
composite
slab 406, which is visible above module 400B but spans the roofs of modules
400A and
400B. Composite slab 406 comprises concrete integrated with shear connector
arrays 116
of modules 400A and 400B (not visible in Figure 14) and shear connectors 474
of a beam
soffit member between modules 400A and 400B (not visible in Figure 14). The
concrete
of composite slab 406 conforms to the corrugated roofs of modules 400A and
400B (not
visible in Figure 14). In some embodiments, curable material introduced to a
slab volume
may be further integrated with the roof(s) the module(s) in order to engage
the steel of the
modules in composite action, such as with adhesive, embosses, shear
connectors, welded
wire mesh and/or the like.
[0142] Step 310 of method 300 comprises providing two modules in spaced
laterally
adjacent relation, each module having one or more shear connectors extending
toward the
other module. This is illustrated in Figure 14 by the laterally adjacent
relation of modules
400A and 400B, and the laterally adjacent relation of modules 400B and 400C.
Step 310
may comprise placing orifices 16 of adjacent corner fittings 14 of the modules
onto
projections of spacers 180 of previously placed modules or onto projections
installed in a
foundation or the like, for example.
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[0143] Step 312 of method 300 comprises enclosing vertically-extending sides
of one or
more volumes between the modules provided in step 310, which volume(s)
includes one
or more shear connectors of the modules. In the illustrated embodiment, step
312
comprises steps 314 and 316.
[0144] Step 314 comprises laterally enclosing a beam volume. In some
embodiments,
step 314 comprises closing vertically extending sides of a beam volume whose
other
vertically extending sides are defined by bottom side rails 46. For example,
step 314 may
comprise installing column closure members, such as members 160, for example,
between adjacent modules 100. The differences between beam volume 446BC and
beam
volume 446AB exemplify step 314. Beam volume 446BC is closed on two of its
vertically extending sides by adjacent bottom side rails of modules 400B and
400C, but is
open on its other vertically-extending sides. Beam volume 446AB is closed on
two of its
vertically-extending sides by adjacent bottom side rails of modules 400A and
400B and
closed another of its other vertically-extending sides by column closure
member 160AB.
The remaining vertically extending side of beam volume 446AB is closed by a
column
closure member not visible in the view shown in Figure 14, so that beam volume
446AB
is laterally enclosed.
[0145] It will be appreciated that where step 310 comprises providing two
modules in
spaced laterally adjacent relation above a slab (e.g., a slab formed in step
308), the slab
may close a bottom side of a beam volume between the modules (e.g., in Figure
14 the
top of composite slab 406 is level with the bottoms of the bottom side rails
of module
400D). In this connection, it may be observed that step 314 may comprise
closing
vertically extending sides of a beam volume that includes shear connectors
embedded in
a slab below the beam volume. This is exemplified in Figure 14 by shear
connectors 474
of beam soffit member 470, which extend above the top of concrete slab 406,
and into the
beam volume that may be formed above beam soffit member 470.
[0146] Step 316 comprises laterally enclosing one or more column volumes. In
some
embodiments, step 316 comprises closing vertically extending sides of a column
volume.
For example, step 316 may comprise installing column closure members, such as
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members 150 and 160, for example, between adjacent modules. The differences
between
column volume 428BC and column volume 428AB exemplify step 316. Column volume
428BC has two vertically-extending sides closed by opposed panel sections 128
of
modules 400B and 400C, and includes shear connector arrays 1120 of modules
400B and
400C. The other two vertically-extending sides of column volume 428BC are
open.
Column volume 428AB has two vertically-extending sides closed by opposed panel
sections 128 of modules 400A and 400B, and includes shear connector arrays of
modules
400A and 400B (not visible in Figure 14). The other two vertically-extending
sides of
column volume 428AB are closed by column closure members 150AB and 160AB, so
that column volume 428AB is laterally enclosed.
[0147] In some embodiments, steps 310, 312, 314 and/or 316 may be combined.
For
example, column closure members may be attached to a first module before the
module is
placed in spaced laterally adjacent relation with a second module. For another
example,
installing column closures 316 may simultaneously constitute all or part of
both steps 314
and 316.
[0148] Step 318 comprises introducing curable material, such as concrete, for
example,
into a laterally-enclosed volume between the modules placed in laterally
adjacent relation
in step 310. In the illustrated embodiment, step 318 comprises steps 320 and
322.
[0149] Step 320 comprises introducing curable material to a beam volume
enclosed in
step 314. Figure 14 shows an example of step 320 in composite beam 404.
Composite
beam 404 is closed on all but one of its vertically extending sides by a
bottom side rail 46
of module 400D (not visible in Figure 14) and column closure members 160D0 and
160DC, and closed on its bottom side by composite slab 406. Ordinarily beam
404 would
be closed on its remaining vertically-extending side, such as by the bottom
side rail of a
module above module 400B. The concrete of beam 404 may have been formed
according
to step 320 by introducing concrete to the form defined by the components
closing the
vertically-extending sides of beam 404. Composite beam 404 comprises concrete
integrated with shear connectors (not visible in Figure 14) of a diaphragm
beam
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anchoring member (not visible in Figure 14) that bridges the space between
modules
400A and 400B.
[0150] Step 322 comprises introducing curable material, such as concrete, for
example,
to a column volume enclosed in step 316. Figure 14 shows examples of step 322,
namely:
= column volume 428AB, which is located between the opposed panel sections
128
of modules 400A and 400B, is laterally enclosed and filled with concrete
(concrete not visible in Figure 14) to form a composite column 402AB,
= column volume 428D, which closed on all but one of its vertically
extending sides
by panel 128 of module 400D (this panel not visible in Figure 14) and column
closure members 150D0 and 160D0, is filled with concrete visible through an
open side of volume 428D to form a composite column 402D, and
= column volume 438D, which is closed on all but one of its vertically
extending
sides by panel 138 of module 400D (this panel not visible in Figure 14) and
column closure members 150DC and 160DC, is filled with concrete visible
through an open side of volume 438D to form a composite column 403D.
[0151] It will be appreciated that the open sides of column volumes 428D and
438D are
open for illustrative purposes, and would ordinarily be closed on their
remaining
vertically-extending sides, such as by panel sections 128 and 138,
respectively, of a
module laterally adjacent to module 400D. The concrete of columns 402D and
403D may
have been formed according to step 322 by introducing concrete to the forms
defined by
the components closing the vertically-extending sides of columns 402D and
403D.
[0152] In some embodiments, two or more of steps 308, 318, 320 and 322 are
combined.
For example, curable material forming a slab and a beam may be introduced
after the
upper modules 100 whose bottom side rails 46 define the beam volume have been
placed
above the slab volume. In such embodiments, the bottom of floor frame 62 of
the module
100 above the slab may be left open to permit curable material to enter the
space between
floor joists 68, or it may be closed (in whole or in part) to prevent curable
material from
filling (at least some of) the space in floor frame 62. In some embodiments,
concrete is
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introduced into forklift pockets 72 and/or between pairs of joists 68 (such as
through
holes defined in a bottom side rail 46 and/or floor panel 70) to form
transverse beams. In
some such embodiments, slabs may not be provided between floors of the
building (e.g.,
transverse beams acting in composite with the module floor may alone provide
sufficient
strength in the diaphragm to carry lateral forces to shear walls). In some
embodiments,
curable material is introduced between modules in step 318 to form continuous
walls
(e.g., detachable panel sections 104 may not be removed from modules 100).
[0153] As the arrangement of modules 400A, 400B and 400C in Figure 14 shows,
method 300 may be practiced with more than two side-by-side adjacent modules.
Method
300 may also be practiced with modules provided in spaced end-to-end adjacent
relation,
end-to-side adjacent relation, and various combinations of spaced side-by-side
adjacent,
end-to-end adjacent, and/or end-to-side adjacent modules.
[0154] Method 300 may be repeated to construct higher floors of a building.
Where this
is done, step 310 may comprise placing modules 100 of an upper floor above the
modules
of an immediately lower floor (e.g., in the manner of module 400D above module
400A).
In some embodiments, an upper module may be mounted above a lower module so
that
the orifices 16 of the upper module's lower corner fittings 14 receive the
projections of
spacers mated with the orifices 16 of corresponding upper corner fittings 14
of the lower
module.
[0155] Advantageously, the use of spacers 180 to separate vertically adjacent
modules
may permit method 300 to be repeated for a higher floor without waiting for
the concrete
poured in the lower floor to cure. In multi-story reinforced concrete
construction, the
usual practice is to shore a freshly placed floor on a previously cast floor.
The sequence
and rate of erection is governed by the loads placed on the supporting
floor(s) by the
weight of the wet concrete and formwork, and by the time required to allow the
concrete
to cure, remove formwork and shoring from the cured concrete and then
reinstall the
formwork and shoring for the next floor. Method 300 may be performed in a
manner that
eliminates at least some of these delays. For example, where spacers 180
placed on the
top corner fittings 14 of the lower modules 100 are at least equal in height
to the depth of
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a slab to be poured over the roofs of the lower modules 100, the next, higher
floor of
modules 100 may be installed and concrete for that floor poured without
shoring before
the concrete of the lower floor has completely cured, since the spacer 180
will transfer
the weight of the upper modules 100 to the lower modules 100 without putting
pressure
on the slab in an early stage of curing.
[0156] Figure 15 is an isometric view of a corner 500 of four adjacent modules
100
(individually identified as 500A, 500B, 500C and 500D) assembled according to
an
example implementation of method 300. Corner 500 includes components
previously
introduced, and like numbers are used to indicate like components without
further
elaboration. In Figure 15, components are layered to expose the internal
elements of
composite columns 502, composite beam 504 and composite slab 506, and to show
detail
of a composite diaphragm 508 formed by the method 300. Diaphragm 508 may be
viewed as a "sandwich", having:
= a bottom that includes plate 172 of beam soffit member 170, and top
panels 58
and top opening end rails 24 of modules 500A and 500B;
= a middle that includes shear connectors 174 of beam soffit member 170,
shear
connector arrays 116 of modules 500A and 500B, and composite slab 506; and
= a top of that includes beam 504 and floors 60 of modules 500C and 500D
(floors
60 and beam 504 being structurally integrated by opposed shear connector
arrays
114 on adjacent bottom side rails 46 of modules 500C and 500D).
[0157] Diaphragm 508 may also be seen as including a grid of composite beams
that
span the full height of diaphragm 508. The beams' cross-sections are defined
in part by
beam soffit members 170 and bottom side rails 46, and the beams include the
full lengths
of shear connectors 174 of beam soffit members 170. Under gravity loads,
plates 172 of
beam soffit member 170 acts as tension flanges of the beams, while bottom side
rails 46
and the concrete encasing shear connectors 174 act as compression members.
[0158] The layers of diaphragm 508 are anchored to one another by shear
connectors. In
particular, shear connector arrays 116 of modules 500A and 500B are embedded
in
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composite slab 506 to anchor the bottom of diaphragm 508 to the middle of
diaphragm
508, and shear connectors 174 of beam soffit member 170 anchor the bottom,
middle and
top of diaphragm 508 together. Anchored as such, the top of diaphragm 508,
which
includes bottom side rails 46, floor joists 68 and plywood panels 70 of
modules 500C and
500D, provides ductile strength against lateral loads and the middle and
bottom of
diaphragm 508 (e.g., concrete slab 506 and top panels 58) provide rigidity.
Advantageously, diaphragm 508 provides this combination of ductile strength
and
rigidity in a shallow floor section and with a beam structure in the same
plane as the
floors 60 of modules 100. In some embodiments, diaphragm 508 is structurally
connected
to a building core (e.g., see building 1000 of Figures 28-31), and carries
lateral forces to
the core to continue the load path through the core to the foundation.
[0159] Figure 15 also shows how column closure members 150 and 160, panel
section
128 and corner posts 28 encase the column concrete to form composite column
502.
Each of the aforementioned structural components is further integrated with
the column
concrete by rigidly connected shear connector arrays (e.g., shear connector
array 1120,
which is visible in Figure 15), which bond with the column concrete. In the
composite
structural members column 502, beam 504, slab 506 and diaphragm 508, the steel
of
modules 500 and column closure members 150 and 160 provide ductility and
tensile
strength for withstanding lateral loads, and the concrete provides structural
rigidity and
compressive strength for withstanding gravity loads. The bonding of the steel
and
concrete with shear connectors combines the structural advantages of both
materials to
deliver structural performance that exceeds the performance of the individual
materials
acting alone.
[0160] The encasement of concrete by steel plates in columns 502 and beam 504
provides advantages over conventional reinforced concrete. In a conventional
reinforced
concrete column or beam the concrete is retained by embedded steel rebar
stirrups closely
spaced along steel rebar. When a reinforced concrete column or beam is loaded
to failure
the concrete spalls away from the rebar stirrups, the rebar bends and the
column or beam
fails. By contrast, in an encased composite concrete column or beam, ductile
steel, which
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is well adapted to withstand lateral tensile loads (such as occur during
seismic event), is
provided on the exterior of rigid concrete, which is well adapted to withstand
vertical
compressive loads. When the column or beam concrete is loaded to failure, it
is confined
by the steel confining it and will continue to carry compressive loads even as
it begins to
fail. An additional advantage is provided by anchoring the encasing steel
plate to the
confined concrete with shear connectors. This anchoring arrangement holds the
steel
encasement flush against the envelope of the concrete, and thereby provides
additional
resistance to buckling.
[0161] The strength of the encasement of columns and beams in method 300 will
depend
on the strength of the connection between the members that form the
encasement. In
some embodiments, members that form encasements are continuously bonded at
their
adjacent edges, such as by welding, adhesive or the like, to provide
additional strength to
columns. In some embodiments, members are joined at spaced apart locations
(i.e., non-
continuously), such as by tack welds, adhesives and/or mechanical connection,
for
example. In some embodiments, members are not permanently joined, and clamps
or
other devices are used to hold the members together while the curable material
they
contain has not cured.
[0162] In some embodiments, ties or stringers may be installed between opposed
encasing members. For example, stringers may be welded between the opposed
surfaces
of adjacent panels 128 and 138 and/or between opposed column members 150 and
160.
For another example, a tie comprising a headed bolt with a threaded shank may
be
inserted through matched holes on opposed encasing members, so that the head
and the
end of the shank are on the outsides of the opposed members, and a nut
threaded on the
end of the shank to prevent the members from moving laterally apart from each
other.
Ties and/or stringers installed between opposed encasing members may function
as both
shear connectors and encasement reinforcement.
[0163] Many variations on the construction of column 502, beam 504, slab 506,
diaphragm 508 and the interconnection of column 502 and beam 504 are possible.
The
particular construction of the column, beam, slab and diaphragm and
interconnection
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between column and beam shown in Figure 15 are non-limiting examples. The
construction of column 502, beam 504, slab 506, diaphragm 508 and the
interconnection
of column 502 and beam 504 shown in Figure 15 may be modified to satisfy
design
criteria. Figures 16, 17 and 18 show composite beams according to other
example
embodiments.
[0164] Figure 16 is a cross-section through a composite beam 604 according to
another
example embodiment. Beam 604 is formed at the interface of four modules 600A,
600B,
600C and 600D. Beam 604 differs from beam 504 in that beam soffit member 670
of
beam 604 is supported by a ledger angle 614 fastened below the top side rails
44 of lower
modules 600A and 600B. As a result, steel plate 672 of beam soffit member 670
is flush
with the top of top side rails 44 of lower modules 600A and 600B, which
provides further
lateral stability.
[0165] Figure 16 demonstrates that a beam soffit member may be lowered
further. This
may be done, for example, by providing modules 100 with side wall panels that
extend
along and below the top side rails. In the context of a module based on an
intermodal
shipping container, this may be effected by removing side panel sections that
do not
extend up to the top side rails, for example.
[0166] Figure 17 is a cross-section through a beam 704 according to a further
example
embodiment. In this embodiment, a beam soffit member 770 comprises a steel I-
beam
772 having shear studs 774 extending from its upper flange 776. Lower flange
778 of I-
beam 772 is supported on ledger angles 714 fastened to the upper portions of
side walls
708 of lower modules 700A and 700B. I-beam 772 is dimensioned so that its
upper
flange 776 rests atop top side rails 44 of lower modules 700A and 700B. Shear
studs 774
extend upward from top flange 776 through concrete slab 706 into the space
between
bottom side rails 46 of upper modules 700C and 700D. As compared with beams
504 and
604, beam 704 has greater strength and may allow for longer spans and/or
heavier floor
loads.
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[0167] Figure 18 is a cross-section through a beam 804 according to a yet
another
example embodiment. In this embodiment, a beam soffit member 870 comprises a
steel I-
beam 872. Lower flange 874 of I-beam 872 is supported on ledger angles 814
fastened to
the upper portions of side walls 808 of lower modules 800A and 800B. The web
876 of I-
beam 872 extends through concrete slab 810 and into beam 804. The upper flange
878 of
I-beam 872 is located in the space between opposed bottom side rails 46 of
upper
modules 800C and 800D. Upper flange 878 of I-beam 872 acts as a shear
connector to
bond concrete in beam 804 to I-beam 872. Web 876 and/or upper flange 878 of I-
beam
872 may be perforated, embossed, or provided with tabs, for example, to
further integrate
it in composite action with the concrete of beam 804. As compared with beams
504, 604
and 704, beam 804 has greater strength and may allow for longer spans and/or
heavier
floor loads. Alternative encased steel joist designs (e.g., castegated beams
or trussed
joists) may also be employed in the manner of I-beams 772 and 872.
[0168] Figure 19 is a cross-section end view of a composite beam 604'
according to
another example embodiment. Beam 604' is a long beam formed between modules
600C'
and 600D', parallel to the side rails of the modules. Beam 604' differs from
beam 604 in
that, like beam 504, beam soffit member 670' of beam 604' is supported by top
side rails
44 of lower modules 600A' and 600B'. Shear studs 674' of beam soffit member
670'
extend into beam 604'. Further composite action is provided by shear bolt 680'
extending
between the bottom side rails 46 of upper modules 600C' and 600D'.
[0169] Figure 20 is a cross-section end view of a composite beam 604"
according to
another example embodiment. Beam 604" is a short beam formed between modules
600C" and 600D". Beam soffit member 670" of beam 604" is supported by top end
rails 12,24 of lower modules 600A" and 600B". Shear studs 674" of beam soffit
member 670" extend into beam 604". Further stability is provided by shear bolt
680"
extending between the bottom end rails 26,36 of upper modules 600C" and 600D".
[0170] Figure 21 is an isometric view of a spacer 980 according to another
example
embodiment. Whereas spacer 180 is configured for aligning and spacing up to
four
adjacent modules 100, spacer 980 is configured for aligning and spacing two
vertically
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adjacent modules. Spacer 980 comprises a steel box 982 which may be closed on
all sides
or open on two sides to allow concrete to enter the void there by providing
composite
connection. Spacer 980 comprises a first projection 984A on one side of box
982 that is
opposite a second projection 984B on the opposite side of box 982. In the
illustrated
embodiment, projections 184 are configured to be received in the orifices 16
of corner
fittings 14 of ISO standard intermodal shipping containers. Shear connector
988A and
988B also extend from opposite side of box 982 between projections 984A and
984B.
[0171] Figure 22 is an isometric view of an assembly 900 according to an
example
embodiment. Assembly 900 partially defines a plurality of volumes into which
curable
material (e.g., concrete) may be introduced to form composite structural
members (e.g.,
beams, columns, slabs, etc.). Assembly 900 comprises:
= volumetric construction module 100;
= a plurality of column closure members 950 and 960 (individually
identified in
Figure 22 as column closure members 9500, 950C, 9600 and 960C), each of
which is identical to column closure member 150;
= a beam soffit member 970, which is a shorter version of beam soffit
member 170;
and
= a plurality of spacers 980
[0172] Assembly 900 also comprises components of assembly 200, which are not
described again here. For convenience, features of the aforementioned
components are
identified using the same reference numerals as in their descriptions above,
and are not
described again here.
[0173] In assembly 900, column closure members 9500 and 950C are generally
perpendicular to and abut inward edges of panel sections 128 and 138,
respectively.
Column closure members 9600 and 960C are generally parallel to and abut
outward
edges of panel sections 128 and 138, respectively. Column closure members 9500
and
9600 close vertically-extending sides of opening end column volume 928. In
like fashion
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column closure members 950C and 960C close vertically-extending sides of
closed end
column volume 938. The open vertically-extending sides of column volumes 928
(opposite panel section 128 and column closure member 9600) and 938 (opposite
panel
section 138 and column closure member 960C) may be closed by an adjacent
volumetric
construction module or another column closure member, so that column volumes
928 and
938 are laterally enclosed.
[0174] Column closure member 9600 extends above a beam volume 946. One
vertically-
extending side of beam volume 946 is closed by opening end bottom rail 26.
Beam
volume 946 includes shear connector array 1180, which projects from rail 26.
The
vertically-extending side of beam volume 946 opposite rail 26 may be closed,
such as by
a bottom rail of another module (e.g., an end bottom rail of a module in end-
adjacent
relation with module 100 of assembly 900, etc.). A beam soffit member 970 is
below and
spaced apart from opening end bottom rail 26. One end of beam soffit member
970 is
aligned with column closure members 9600. Shear connectors 974 of beam soffit
member 970 extend into beam volume 946. It will be appreciated that beam
volume 946
is continuous with beam volume 246 defined by assembly 200 (see Figure 12),
and that a
grid of continuous composite beams may be provided by arranging modules 100 in
a
rectangular array and introducing curable material to these beam volumes.
[0175] Figure 23 is a flowchart of a construction method 300' according to an
example
embodiment. Figures 24 is an isometric view of an assembly 400' of six
volumetric
construction modules 100 (individually identified in Figure 24 as 400A',
400B', 400C',
400D', 400E' and 400F') illustrating stages of construction according to an
example
implementation of method 300'. Modules 400A', 400W, 400C' and 400D' are part
of a
first floor. Modules 400E' and 400F' are located on top of modules 400A' and
400C',
respectively, as part of a second floor. Modules 400A', 400B', 400C', 400D',
400E' and
400F' are shown without doors 52, closed panels 54 and detachable sections 104
in
Figure 24 to avoid obscuring features of assembly 400'. In some embodiments,
one or
more of these components is left in place at one or more of the illustrated
stages of
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construction (e.g., for hoarding and/or shoring until concrete has cured, for
permanently
dividing adjacent modules, for providing exterior walls, etc.).
[0176] The first floor of assembly 400' also comprises an expansion space
450A' in a
side-by-side arrangement between modules 400A' and 400B', and an expansion
space
450B' in a side-by-side arrangement between modules 400C' and 400D'. Expansion
spaces 450A' and 450B' are illustrated with a width equal to that of the
modules. In other
embodiments expansion spaces 450A' and 450B' may be narrower or wider than the
modules. An expansion space provides assembly 400' with additional interior
space at a
lower cost than adding a module. Expansion spaces may for example be provided
in
sections of assembly 400' where structural requirements can be met without the
need for
adding modules.
[0177] Figure 25 shows a portion of assembly 400'. Panel expansion member 475'
is
supported by and spans corresponding top side rails 44 of modules 400A' and
400B' to
partly define expansion space 450A'. Figure 26 is a close up view of panel
expansion
member 475' being supported by top side rail 44 of module 400A'. As shown in
Figure
25, a supplemental floor frame 462' between the floor frames 62 of modules
400A' and
400B' partly defines expansion space 450A'. Figure 26 is a close up view of
supplemental floor frame 462' of an expansion space 450C' built above
expansion space
450A', wherein supplemental floor frame 462' is tied to floor frame 62 of
adjacent
module 400E' by shear bolts of shear connector array 114. Supplemental floor
frame
462' of expansion space 450A' may be tied in a similar manner to floor frames
62 of
modules 400A' and 400B' in Figure 25. Supplemental floor frame 462' may be
similar in
construction to floor frame 62.
[0178] In other embodiments, expansion spaces may be provided in an end-to-end
arrangement between modules, for example as shown in close up in Figure 27
which
illustrates a partial view of two stacked modules 410A' and 410C' on the left
of the
figure and two stacked expansion spaces 415A' and 415B' on the right of the
figure.
Panel expansion member 475' spans from top opening end rail 24 of module 410A'
to a
top end rail of module 410B' (not shown). Floor frame 462' of expansion space
415B' is
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tied to floor frame 62 of module 410C' by bolts of shear array 1180. Plywood
flooring
495' covers floor frame 62 and 462'. Method 300' may also be practiced with
expansion
spaces between modules provided in spaced end-to-end adjacent relation, end-to-
side
adjacent relation, and various combinations of spaced side-by-side adjacent,
end-to-end
adjacent, and/or end-to-side adjacent modules.
[0179] Figure 25 also shows column reinforcement members 465'extending from
base
regions of corner posts 28,38 to mid-elevation regions of the second floor of
assembly
400' (as also shown in Figure 24). The columns of assembly 400' differ from
the
columns of assembly 400 in that they include column reinforcement members 465'
which, together with corner posts 28,38, are encased in a curable material
such as
concrete to form composite columns. Example configurations of column
reinforcement
members 465' and column posts 28,38 within composite columns are shown in
Figures
35-37 and 40. Concrete on the exterior of the composite columns adds a fire
rating to
assembly 400', and further adds strength to the columns' axial, shear and
bending
capacity.
[0180] As shown in Figure 25, formwork 480' may be positioned to define the
column
volume and to contain the curable material, such as concrete, until it cures.
Shoring 490'
may also be temporarily positioned along the center of the modules to support
the top
panels 58 of the modules, and along the center of the expansion spaces to
support the
expansion panel member 475', while curable material for composite slab 406' is
poured
and cured above. Formwork 480' and shoring 490' are not shown in Figures 24
and 24A
for simplicity and clarity.
[0181] Construction method 300' as illustrated in Figure 23 is similar to
construction
method 300 of Figure 13 except that construction method 300' contemplates (i)
including
expansion spaces (e.g. expansion spaces 450A', 450B', 450C', 450D', 415A',
415B')
between one or more pairs of laterally aligned modules and/or (ii) increasing
strength of
the assembly by forming composite columns with additional column closure
members
embedded within formed columns of curable material (e.g. high-strength
concrete, carbon
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fibre reinforced polymer (CFRP), and the like). In particular, differences
between
construction method 300' and construction method 300 may include the
following:
= step 304' ¨ where the perimeter of an assembly includes one or more
expansion
spaces, enclosing the lateral sides of a slab volume may additionally comprise
installing slab edge closures 190 above the perimeter edges of panel expansion
members. When an expansion space is adjacent a module and there are no other
adjacent modules, then a spacer 980 instead of a spacer 180 may be installed
on
the top orifice of the corner fitting of the module to allow vertical stacking
of
additional modules.
= step 306' ¨ panel expansion members of expansion spaces are sized so that
their
side edges abut the top panel edges of laterally adjacent modules so no
additional
bridging is necessary. See for example the arrangement of panel expansion
member 475' and top panels 58 in Figure 24A.
= step 308' ¨ the composite slab may alternatively or additionally span the
roofs of
modules and expansion spaces. The composite concrete slab may additionally
comprise shear connectors of panel expansion members. The curable material of
the composite concrete slab conforms to the corrugated top panels of the
modules
and the corrugated top surface of panel expansion members of the expansion
spaces. See for example in Figures 24A, 26 and 27 the integration of the shear
connectors of panel expansion members 475' with slab 406'. In some
embodiments, curable material introduced to a slab volume may be further
integrated with the panel expansion members in order to engage the steel of
the
expansion spaces in composite action, such as with adhesive, embosses, shear
connectors, welded wire mesh and/or the like.
= step 310' ¨ this step may alternatively or additionally comprise providing
an
expansion space between two laterally aligned modules, as shown for example in
Figure 25. Step 310' therefore can comprise spanning top side rails of
laterally
aligned and spaced apart modules with a panel expansion member, and installing
between the bottom side rails of the modules a supplemental floor frame, to
define
an expansion space. Instead of the side-by-side configuration shown in Figure
25,
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an expansion space may be provided in an end-to-end configuration, as
partially
shown in Figure 27 and described above. Orifices of corner fittings of modules
adjacent an expansion space would be placed on projections of spacers 180 or
980
of previously placed modules or onto projections installed in a foundation or
the
like, for example.
= step 312' ¨ this step may alternatively or additionally comprise
enclosing
vertically-extending sides of one or more volumes between modules and
expansion spaces.
= step 314' ¨ laterally enclosing a beam volume may alternatively or
additionally
comprise closing vertically extending sides defined on one side by a bottom
side
rail or bottom end rail of a module and on the other side by a bottom side
rail or
bottom end rail of a supplemental floor frame of an expansion space. The ends
of
the beam volume may be closed by formworks for a column instead of a column
closure member as in step 314. Where a slab closes a bottom side of a beam
volume between a module and expansion space (e.g. in Figure 24A, the top of
composite slab 406' is level with the bottoms of the bottom side rail of
second
floor module 400F' and the bottom side rail of supplemental floor frame of
second floor expansion space 450D'), step 314' would include comprise closing
vertically extending sides of a beam volume that includes shear connectors of
panel expansion member 475' extending through the top of slab 406' into the
beam volume. This is shown with long (i.e., side) beam volume 446' in Figure
26
and short (i.e., end) beam volume 447' in Figure 27.
= step 316' ¨ laterally enclosing a column volume may alternatively or
additionally
comprise temporarily positioning formworks along one, two, three or all four
vertically extending sides of a column of an assembly. For example, Figure 25
illustrates formworks 480' temporarily positioned on two sides of each of the
four
columns illustrated. Formworks 480' for the other two sides (i.e., the ends)
are
not shown. Each column also comprises column reinforcement member 465'. In
some embodiments column reinforcement members 465' are bolted with shear
bolts to corner posts of the modules. Example configurations of column
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reinforcement members with shear connectors of the module corner posts within
the columns are shown in Figures 35-37 and 40.
= step 318' - this step comprises introducing curable material, such as
concrete, for
example, into a laterally-enclosed slab volume between the modules and
expansion spaces placed in laterally adjacent relation in step 310'.
= step 320' ¨ this step comprises introducing curable material, such as
concrete, to a
beam volume enclosed in step 314'. Beam 446' and 447' in Figures 26 and 27 are
examples of cured beam volumes.
= step 322' ¨ this step comprises introducing curable material, such as
concrete, to a
column volume enclosed in step 316'. Column 402 in Figures 24 and 24A are
examples of cured column volumes.
= step 324' ¨ formworks and shoring are removed once curing material has
cured.
[0182] Method 300' may be repeated to construct higher floors of a building.
Where this
is done, step 310' may comprise placing modules 100 of an upper floor above
the
modules of an immediately lower floor (e.g., in the manner of module 400E'
above
module 400A') and placing expansion spaces of an upper floor above expansion
spaces
of an immediately lower floor (e.g. in the manner of expansion space 450C'
above
expansion space 450A'). In some embodiments, an upper module may be mounted
above
a lower module so that the orifices 16 of the upper module's lower corner
fittings 14
receive the projections of spacers mated with the orifices 16 of corresponding
upper
corner fittings 14 of the lower module.
[0183] Figure 27A is an isometric view of a corner 500' of four adjacent
modules
assembled according to another example implementation of method 300' without
any
expansion spaces. Curable material is introduced into formwork to form column
502'
during step 322' of an initial cycle of method 300' for construction of the
floor beneath
the four adjacent modules. Subsequently, curable material is introduced to
form slab
506' during step 308' of a subsequent cycle of method 300' for construction of
the floor
comprising the four adjacent modules. Next, curable material is introduced to
form
beams 504' during step 320' the same subsequent cycle of method 300'.
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[0184] Figure 28 is an isometric view of a multi-story building 1000 according
to an
example embodiment. Building 1000 comprises core walls 1002 (which are shear
walls
positioned in a square or rectangular arrangement around stair and or elevator
shafts in
the region of the center of the building; see Figure 41 for an example
embodiment of a
shear wall). Core walls 1002 protrude through the roof as is common in mid-
rise and
high-rise buildings. The first floor 1004 of building 1000 is a concrete
substructure (e.g.,
a commercial structure, a parking garage, a foundation at grade, etc.).
Modules 1006 are
stacked twelve stories high and surround core walls 1002 on three sides.
Columns, beams
and diaphragms formed in part by modules 1006 and they are structurally
connected to
one another and lateral loads are carried to core walls 1002 then through the
core walls to
the foundation. Modules 1006 have windows 1008 at their opening ends. Columns
between outward ends of adjacent modules 1006 are hidden by a building
envelope 1010.
[0185] Figure 29 is a floor plan 1100 of multi-story building 1000, shown
without
modules 1006 and certain interior elements of building 1000 in order to expose
the
location of core walls 1002, columns 1102 and beams 1104. Columns 1102 are
arranged
in a grid, which provides open spans suitable for various architectural
applications.
Beams 1104 show the rectangular grid of the floor diaphragm 1106 which carries
lateral
loads to the concrete core walls 1102. Though floor plan 1100 shows columns
1102
between every module, in other embodiments, some columns may be eliminated
(e.g.,
columns may be provided between only every second module or every third
module).
Where columns are eliminated, more robust beam designs may be used to support
longer
spans between columns.
[0186] Figure 30 is a floor plan 1200 of a floor of multi-story building 1000,
shown with
modules, interior finishing and fenestration hardware. In floor plan 1200,
modules 1006
are arranged to provide hallways 1210, studio apartments 1220, and building
core 1240.
[0187] Hallways 1210 comprise hall modules 1212 in spaced end-wise adjacent
relation.
Hall modules 1212 comprise frames of 20 foot intermodal shipping containers.
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[0188] Studio apartments 1220 comprise pairs of long side adjacent room
modules 1222.
Room modules 1222 comprise frames of 20 foot intermodal shipping containers.
Room
modules 1222 of each apartment 1220 are connected by openings 1224. Dividing
walls
1226 are provided between pairs of room modules 1222. Dividing walls 1226 may
be
formed by introducing curable material between opposed closed sides of
adjacent
modules room modules 1222 of adjacent apartments 1220. Envelope walls 1228 are
provided at the exterior sides and ends of room modules 1222.
[0189] In each studio apartment 1220, curtain walls 1230 are installed to
create a
bathroom and kitchen space and doors 1232 are fitted in openings of interior
walls 1214
for entry from hallway 1210 to open living spaces of apartments 1220.
[0190] Building core 1240 comprises three core units 1244, 1246 and 1248.
First core
unit 1244 comprises four upright core modules 1242A in spaced laterally
adjacent
relation. Core modules 1242A comprise the frames of 20 foot intermodal
shipping
containers. Second core unit 1246 and third core unit 1248 each comprise a
core module
1242B. Each core module 1242B comprises the frame of a 40 foot intermodal
shipping
container. Second core unit 1246 and third core unit 1248 confine opposite
sides of first
core unit 1244.
[0191] Core walls 1002 are provided between core units 1244, 1246 and 1248,
and on the
outward sides of core units 1244, 1246 and 1248. Core walls may be made more
robust,
such as by increasing their thickness, installing rebar mats, providing shear
connectors or
bolts between panels of core modules 1242 (e.g., by covering an entire side
panel with
shear connectors), and/or laminating additional panels (e.g., detachable panel
sections
removed from room modules 1222) onto them, for example.
[0192] Core modules 1242B of second core unit 1246 and third core unit 1248
are
provided with top and bottom openings. In second core unit 1246, elevator
shafts 1254
are provided through these openings. In third core unit 1248, stairwells 1256
are provided
in these openings.
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[0193] Figure 31 is a cross-section through core 1002 of building 1000. As can
be seen
from Figure 31, core modules 1242B of second core unit 1246 and third core
unit 1248
are provided for every floor, and are integrated with diaphragms 1260 of their
respective
floors. Core modules 1242A of first core unit 1244 are end-wise vertically
stacked, and
each first core unit 1244 spans 3 and 2/3 floors. Vertical core walls 1002
between the
adjacent core units are visible in Figure 30.
[0194] It will be appreciated that the variety of configurations in which
shear connectors
may be provided on modules, closure components, and expansion space components
(e.g.
panel expansion members and supplemental floor frames), combined with the
variety of
configurations in which modules, expansion space components, closure
components, and
reinforcement members may be arranged provides virtually limitless freedom in
the
design of composite structure components. Figures 32-34 show three example
columns
that illustrate how different configurations of modules, shear connectors and
closure
components may be used to provide different column designs. The columns shown
in
Figures 32 to 34 may for example be utilized in assembly 400. Figures 35-40
show six
example columns that illustrate how different configurations of modules, shear
connectors and reinforcement members may be used to provide different column
designs.
The columns shown in Figures 35-40 may for example be utilized in assembly
400L
[0195] Figure 32 is a schematic plan view cross-section through a column 1400
according to an example embodiment. Column 1400 is formed in part by four
corner
adjacent opening end corner posts (individually enumerated as 1410A, 1410B,
1410C
and 1410D, referred to collectively herein as corner posts 1410) of different
modules (not
shown). Each of corner posts 1410 has a plurality of shear connectors 1412
extending
outwardly from it. In Figure 32, it may be observed that opposite ones of
shear
connectors 1412 of adjacent ones of corner posts 1410 are vertically
staggered. More
particularly, in the close laterally adjacent relation of corner posts 1410 in
column 1400,
shear connectors 1412 of opposing shear connector arrays pass by each other in
overlapping fashion.
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[0196] Corner posts 1410 partially laterally enclose a volume 1420. Curable
material is
not shown in volume 1420 in order to avoid obscuring features of column 1400.
The
lateral sides of volume 1420 not enclosed by corner posts 1410 are enclosed by
column
closure members (individually enumerated as 1430A, 1430B, 1430C and 1430D,
referred
to collectively herein as column closure members1430). Each of column closure
members 1430 has a plurality of shear connectors 1432 extending from one of
its major
sides. In Figure 32, it may be observed that the shear connectors 1432 of
column closure
members 1430A and 1430D are vertically staggered with respect to the shear
connectors
1412 of the corner posts 1410 to which column closure members 1430A and 1430D
are
adjacent. More particularly:
= shear connectors 1432 of column closure member 1430A overlap at right
angles
the shear connectors 1412 of shear connector arrays of corner posts 1410A and
1410B, which are bridged by column closure member 1430A; and
= shear connectors 1432 of column closure member 1430D overlap at right
angles
to the shear connectors 1412 of shear connector arrays of corner posts 1410C
and
1410D, which are bridged by column closure member 1430D.
[0197] In Figure 32, it may also be observed that shear connectors 1432 of
opposing
shear connector arrays of column closure members 1430B and 1430C pass by each
other
in overlapping fashion.
[0198] Figure 33 is a schematic plan view cross-section through a column 1500
according to an example embodiment. Column 1500 is formed in part by four
corner
adjacent closed end corner posts (individually enumerated as 1510A, 1510B,
1510C and
1510D, referred to collectively herein as corner posts 1510) of different
modules (not
shown). Each of corner posts 1510 has a plurality of shear connectors 1512
extending
outwardly from it. In Figure 33, it may be observed that opposite shear
connectors 1512
of adjacent ones of corner posts 1510 are vertically staggered. More
particularly, in the
close laterally adjacent relation of corner posts 1510 in column 1500, shear
connectors
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1512 of opposing shear connector arrays of corner posts 1510 pass by each
other in
overlapping fashion.
[0199] Corner posts 1510 partially laterally enclose a volume 1520. Curable
material is
not shown in volume 1520 in order to avoid obscuring features of column 1500.
The
lateral sides of volume 1520 not enclosed by corner posts 1510 are enclosed by
column
closure members (individually enumerated as 1530A, 1530B, 1530C and 1530D,
referred
to collectively herein as column closure members1530). Each of column closure
members 1530 has a plurality of shear connectors 1532 extending from one of
its major
sides. In Figure 26, it may be observed that opposing shear connectors 1532 of
opposite
ones of column closure members 1530 are vertically staggered. More
particularly, shear
connectors 1532 of opposing shear connector arrays pass by each other in
overlapping
fashion. In Figure 26, it may also be observed that the shear connectors 1532
of column
closure members 1530 are vertically staggered with respect to the shear
connectors 1512
of the corner posts 1510 to which column closure members 1530 are adjacent.
More
particularly:
= shear connectors 1532 of column closure member 1530A overlap at right
angles
the shear connectors 1512 of shear connector arrays of corner posts 1510A and
1510B, which are bridged by column closure member 1530A;
= shear connectors 1532 of column closure member 1530B overlap at right
angles
the shear connectors 1512 of shear connector arrays of corner posts 1510A and
1510D, which are bridged by column closure member 1530B;
= shear connectors 1532 of column closure member 1530C overlap at right
angles
the shear connectors 1512 of shear connector arrays of corner posts 1510B and
1510D, which are bridged by column closure member 1530B; and
= shear connectors 1532 of column closure member 1530D overlap at right angles
the shear connectors 1512 of shear connector arrays of corner posts 1510C and
1510D, which are bridged by column closure member 1530D.
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[0200] Figure 34 is a schematic plan view cross-section through a column 1600
according to an example embodiment. Column 1600 is formed in part by two
laterally
adjacent closed end corner posts (individually enumerated as 1610A and 1610B,
referred
to collectively herein as corner posts 1610) of different modules (not shown).
Each of
corner posts 1610 has a plurality of shear connectors 1612 extending from one
of its
major sides. In Figure 34, it may be observed that opposite shear connectors
1612 of
corner posts 1610 are vertically staggered. More particularly, in the close
laterally
adjacent relation of corner posts 1610 in column 1600, shear connectors 1612
of
opposing shear connector arrays of corner posts 1610 pass by each other in
overlapping
fashion.
[0201] Corner posts 1610 partially laterally enclose a volume 1620. Curable
material is
not shown in volume 1620 in order to avoid obscuring features of column 1600.
The
lateral sides of volume 1620 not enclosed by corner posts 1610 are enclosed by
column
closure members (individually enumerated as 1630A, 1630B and 1630C, referred
to
collectively herein as column closure members1630) and laminated panel section
1640.
Each of column closure members 1630 has a plurality of shear connectors 1632
extending from one of its major sides. Laminated panel section 1640 comprises
two panel
sections 1640A and 1640B which have been laminated together. A plurality of
shear
connectors 1642 extend from one side of panel section 1640.
[0202] In Figure 34, it may be observed that the shear connectors 1632 of
column closure
members 1630 are vertically staggered with respect to the shear connectors
1612 of the
corner posts 1610 to which column closure members 1630 are adjacent. More
particularly:
= shear connectors 1632 of column closure member 1630A overlap at right
angles
the shear connectors 1612 of shear connector arrays of corner posts 1610A and
1610B, which are bridged by column closure member 1630A; and
= shear connectors 1632 of column closure member 1630B overlap at right
angles
to the shear connectors 1612 of a shear connector array of corner post 1610A;
and
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= shear connectors 1632 of column closure member 1630C overlap at right
angles
to the shear connectors 1612 of a shear connector array of corner post 1610B.
[0203] In Figure 34, it may also be observed that shear connectors 1642 of
panel section
1640 are vertically staggered with respect to opposed shear connectors 1612 of
corner
posts 1610 and with respect to opposed shear connectors 1632 of column closure
member
1630A. More particularly:
= shear connectors 1642 of panel section 1640 pass by shear connectors 1612
of
opposed shear connector arrays of corner posts 1610 in overlapping fashion;
and
= shear connectors 1642 of panel section 1640 pass by shear connectors 1632
of the
opposed shear connector array of column closure member 1630A in overlapping
fashion.
[0204] Figure 35 is a schematic plan view cross-section through a column 1500
according to an example embodiment. Column 1500 includes two adjacent opening
end
corner posts facing each other (individually enumerated as 1510A and 1510B) of
different modules (not shown). Each of corner posts 1510A, 1510B has a
plurality of
shear connectors 1512 extending outwardly from it. Shear connectors 1512 are
received
in holes of corresponding column reinforcement members 1565A, 1565B and
bolted.
Column 1500 is formed by pouring curing material into a column volume 1520
enclosed
by formwork (not shown).
[0205] Figure 36 is a schematic plan view cross-section through a column 1600
according to an example embodiment. Column 1600 includes two adjacent opening
end
corner posts in a side-by-side configuration (individually enumerated as 1610A
and
1610B of different modules (not shown). One of corner posts 1610A, 1610B has a
plurality of shear connectors 1612 extending outwardly from it, while the
other of corner
posts1610A, 1610B has holes for receiving shear connectors 1612 and creating a
bolted
connection. Alternatively, both corner posts may have a plurality of holes for
receiving a
plurality of separate shear connectors and creating bolted connections. Column
1600 is
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formed by pouring curing material into a column volume 1620 enclosed by
formwork
(not shown).
[0206] Figure 37 is a schematic plan view cross-section through a column 1700
according to an example embodiment. Column 1700 includes an opening end corner
posts 1710. Corner post 1710 has a plurality of shear connectors 1712
extending
outwardly from it and received in holes of a column reinforcement member 1765.
Column 1700 is formed by pouring curing material into a column volume 1720
enclosed
by formwork (not shown).
[0207] Figure 38 is a schematic plan view cross-section through a column 1800
according to an example embodiment. Column 1800 includes two pairs of corner
adjacent opening end corner posts (individually enumerated as 1810A, 1810 B,
1810C
and 1810D of different modules (not shown). One of the corner posts from each
pair of
corner posts has a plurality of shear connectors 1812 extending outwardly from
it, while
the other one of the corners posts from each pair has holes for receiving
shear connectors
1812 and creating a bolted connection. Alternatively, all of corner posts may
have a
plurality of holes for receiving a plurality of separate shear connectors and
creating
bolted connections. Column 1800 is formed by pouring curing material into a
column
volume 1820 enclosed by formwork (not shown).
[0208] Figure 39 is a schematic plan view cross-section through a column 1900
according to an example embodiment. Column 1900 includes two facing closed end
corner posts (individually enumerated as 1910A and 1910B of different modules
(not
shown). One of corner posts 1910A, 1910B has a plurality of shear connectors
1912
extending outwardly from it, while the other of corner posts1910A, 1910B has
holes for
receiving shear connectors 1912 and creating a bolted connection.
Alternatively, both
corner posts may have a plurality of holes for receiving a plurality of
separate shear
connectors and creating bolted connections. Column 1900 is formed by pouring
curing
material into a column volume 1920 enclosed by formwork (not shown).
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[0209] Figure 40 is a schematic plan view cross-section through a column 2000
according to an example embodiment. Column 2000 includes a closed end corner
posts
010. Corner post 2010 has a plurality of shear connectors 2012 extending
outwardly from
it and received in holes of a column reinforcement member 2065. Column 2000 is
formed
by pouring curing material into a column volume 2020 enclosed by formwork (not
shown).
[02101 The structural capacity of any building's design is highly influenced
by its' height
and aspect ratio; further, modern building codes dictate standards for seismic
resistance
based on probability and site soil conditions. Most reinforced high rise
designs combine
core walls with robust beam to column connections to absorb, transfer and
dissipate
lateral loads, therefore axial and lateral forces are linked through these
structures. The
modular structural systems described here provides axial load capacity for
gravity loads,
however, the systems decouple gravity loads and lateral loads. When applied in
a
traditional architectural schemes as described in this disclosure, the system
will have
sufficient inherent lateral load capacity to resist moderate wind and seismic
loads,
however, in areas where the structure is expected to experience high
earthquake or wind
loads, the system can be augmented to increase the load capacity of the
structure by
transferring, isolating and/or dissipating lateral forces. There are several
methods to deal
with this as set out below:
1. Add a seismic force resisting system such as moment frame, shear wall,
braced
frame, dampers, or base isolation to the structure. Excessive lateral loads
can be resisted
by adding dedicated shear walls or braced frames to the structure. (The
lateral loads will
be transferred through the floor diaphragms as lateral forces to the shear
walls or braced
frames and ultimately to the foundation. Figure 41 is a schematic plan view
cross-section
through a shear wall 2100 according to an example embodiment. Shear wall 2100
includes a shear wall volume 2160 defined by a shear wall panel 2104 on one
side and on
the other side a module 2110, beam 2046, and an expansion space 2150. Shear
wall
panel 2104 may comprise repurposed container wall material. A plurality of
connectors
2112, such as ties or stringers, rigidly tie shear wall panel 2104 to
corresponding panels
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or posts of module 2110 and expansion space 2150. Shear wall volume 2160 may
additionally include reinforcing material such as rebar (not shown).
2. Augment the beam to column connections to transfer the moment resulting
from
the lateral loads to the length of the columns and beams, for example:
a) using gusset plates to create haunches at the beam to column connection
and/or
b) adding steel reinforcements within the concrete to make the beam to
column
connection a moment connection.
3. Add base isolation devices to isolate the structure from the foundation.
Dedicated
base isolation devices can be used to absorb most of the earthquake energy and
limit the
lateral forces to be transferred to the modular structural system.
[0211] Shear walls are a practical method of combining structural stability,
architectural
segregation and fire separation between areas of a building and can be
employed
efficiently in architectural applications such as residential apartments,
hospitals, prison
cells and the like.
[0212] Augmenting the beam to column connections is also a practical seismic
solution.
It limits the need for walls and provides open plan architectural
opportunities but
increases the size and weight of the structure which will increase foundation
costs.
[0213] Base isolation provides the most sustainable opportunity as these
buildings are
earthquake resistant because lateral forces are absorbed in the isolators
rather than by
compromising the structure, which is the case for all code prequalified
seismic force
resisting systems. The modular structural system described here provides a
stiff structure
which is ideal for base isolation. Buildings of the present invention may
accordingly
incorporate suitable base isolation systems.
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[0214] Figure 42 is a schematic plan view cross-section through a column 2200
according to an example embodiment. Column 2200 includes two adjacent opening
end
corner posts facing each other (individually enumerated as 2200A and 2200B) of
different modules (not shown). Corner posts 2200A and 2200B have a plurality
of shear
stirrups 2212 (rebar bent into a rectangular loop with lapping splice hooks at
the end)
enclosing the corner posts on one side of the column and vertical rebar
reinforcement
members 2210A, 2210B, 2210C, 2210D and 2210F on the opposing side of the
column.
Column 2200 is formed by pouring curing material into a column volume 2220
enclosed
by formwork (not shown). Similar to column reinforcement member 465' (see
Figure 25)
the vertical rebar reinforcement may extend to midlevel of the floor above for
splicing to
additional members extending to the elevation above. Splicing the vertical
members at
mid floor elevation stiffens the column as it terminates at an alternative
location away
from the beam column connection and it adds shear strength to the beam to
column
connection.
[0215] Figure 43 is a schematic plan view cross-section through a column 2300
according to an example embodiment. Column 2300 includes an opening end corner
post
2300A. Corner post 2300A has a plurality of shear stirrups 2312 enclosing the
corner
posts on one side of the column and vertical rebar reinforcement members
2310A, 2310B
and 2310C on the opposing side of the column. Column 2300 is formed by pouring
curing material into a column volume 2320 enclosed by formwork (not shown).
Similar
to column reinforcement member 465' (see Figure 25) the vertical rebar
reinforcement
may extend to midlevel of the floor above for splicing to additional members
extending
to the following elevation.
[0216] Columns 2200 and 2300 can be implemented in place of column 402', shown
in
Figure 24, with adjacent expansion space. Further columns 2200 and 2300 may be
implemented to integrate the volumetric modular system described here, to a
conventional reinforced concrete building or to a steel structure with Q deck,
etc. It
should be further noted that shear stirrups shown with hooks in Figures 42 and
43 may be
spliced with mechanical connectors, for example LentonTM Quick Wedge or
LentonTM
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Interlock rebar splice. By employing these fittings the shear stirrups may be
more open or
in two or more pieces. This allows the substitution of shear stirrups in place
of the shear
bolts demonstrated in Figures 35 and 36 on columns 1500 and 1600.
[0217] The demonstration of headed studs, shear bolts or shear stirrups as
shear
connectors across columns is not intended to be limiting in that other methods
of
providing shear connection across columns may be employed such as carbon-fiber-
reinforced polymer wrap as used in seismic upgrading columns, etc. may be
employed to
integrate the corner posts of volumetric construction modules in columns.
[0218] Figure 44 is an isometric view of a composite beam 4404 according to
another
example embodiment. Beam 4404 is a long beam formed between modules 600C and
600D (see Figure 16) parallel to the side rails of the modules. Beam 4404
differs from
beam 604 in that the beam soffit member 670 is replaced by a non-structural
soffit form
4471 straddling the top side rails 44 of the adjacent modules to contain the
curable
material and two lengths of structural rebar 4470 are installed a spaced above
the soffit
form 4471 to provide a concrete cover under the rebar for fire rating. Shear
stirrups 4474
are U-shaped with hooks at both ends. The lower horizontal portion of the U
shaped shear
stirrup 4474 passes below the two lengths of structural rebar 4470 and the two
vertical
portions extend into the upper section of beam 4404. Further confinement of
the concrete
and composite action in the beam is provided by shear bolt 680 extending
between the
bottom side rails 46 of upper modules 600C and 600D and the vertical portions
of shear
stirrup 4474 with the hooked ends around shear bolt 680.
[0219] Figure 44A is a cross section end view of composite beam 4404.
[0220] Figure 45 is a cross section end view of composite beam 4504 according
to a
further example embodiment. Beam 4504 is a long beam formed between module
600C
and a panel expansion member with a supplemental floor frame. Beam 4504 is
similar to
beam 446' of Figure 26 except there is no beam soffit member below the
expansion
panel. Instead there are two lengths of structural rebar 4470 spaced above the
panel
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expansion member to provide a concrete cover under the rebar for fire rating.
Shear
stirrups 4474 are employed in the same manner as in beam 4404.
[0221] Figure 46 is a cross section end view of composite beam 4604 according
to a yet
further example embodiment. Beam 4604 is an alternative short beam formed
between
module 600A" and 600B" of Figure 20. Beam 4604 differs from beam 604" in that
beam soffit member 670" is replaced by a non-structural form 4671 straddling
the top
end rails of the adjacent modules to contain the curable material. Two lengths
of
structural rebar 4670 are spaced above the soffit form 4671 to replace the
structural
contribution of beam soffit member 670" and provide a concrete cover over the
rebar for
fire rating. Shear stirrups 4674 are U shaped with hooks at both ends. The
lower
horizontal portion of the U-shaped shear stirrup 4674 passes below the two
lengths of
structural rebar 4670 and the two vertical portions extend into the upper
section of beam
4604. Further confinement of the concrete and composite action in the beam is
provided
by shear bolt 680 extending between the bottom end rails of the upper modules
600C"
and 600D" and the vertical portions of shear stirrup 4474 with the hooked ends
around
shear bolt 680.
[0222] Figure 47 is a cross section end view of composite beam 4704 according
to an
example embodiment similar to Figure 27 in that the beam is closed on one side
by the
bottom end rail of a module and on the other by a framed floor above an
expansion panel.
Beam 4704 differs from Figure 27 in that instead of a beam soffit member,
there are two
lengths of structural rebar 4470 installed at a spaced distance above the an
expansion
panel to allow a concrete cover under the rebar for fire rating. Shear
stirrups 4774 are U
shaped with hooks at both ends. The lower horizontal portion of the U shaped
shear
stirrup 4774 passes below the two lengths of structural rebar 4770 and the two
vertical
portions extend into the upper section of beam 4704. Further confinement of
the concrete
and composite action in the beam is provided by shear bolts 680 extending
between the
bottom rails of the upper modules and the vertical portions of shear stirrup
4474 with the
hooked ends around shear bolt 680. It should be noted that a similar beam
configuration
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may employed between facing expansion panels and floor frames or with a bottom
side
rail of a module on one side only, for example, at the edge of a building.
[0223] The capacity of the columns and beams described in Figures 42 to 47 may
be
adapted to the buildings structural demand by varying the cross section of
concrete, the
size and quantity of vertical rebar members and the size, quantity, location
and spacing of
the shear stirrups. Further, the capacity of the beam to column connection may
be
augmented by employing standard lapped rebar details with hooked stirrups
employing
engineering methods that are well understood by those familiar with the art.
[0224] Where a component or feature is referred to above (e.g., container,
frame, rail,
post, joist, panel, C-channel, plate, module, shear connector, etc.), unless
otherwise
indicated, reference to that component (including a reference to a "means")
should be
interpreted as including as equivalents of that component any component which
performs
the function of the described component (i.e., that is functionally
equivalent), including
components which are not structurally equivalent to the disclosed structure
which
performs the function in the illustrated exemplary embodiments of the
invention.
[0225] Unless the context clearly requires otherwise, throughout the
description and the
claims, the words "comprise," "comprising," and the like are to be construed
in an
inclusive sense, as opposed to an exclusive or exhaustive sense; that is to
say, in the sense
of "including, but not limited to." Where the context permits, words in the
above
description using the singular or plural number may also include the plural or
singular
number respectively. The word "or," in reference to a list of two or more
items, covers all
of the following interpretations of the word: any of the items in the list,
all of the items in
the list, and any combination of the items in the list.
[0226] The above detailed description of example embodiments is not intended
to be
exhaustive or to limit this disclosure and claims to the precise forms
disclosed above.
While specific examples of, and examples for, embodiments are described above
for
illustrative purposes, various equivalent modifications are possible within
the scope of
the technology, as those skilled in the relevant art will recognize.
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[0227] These and other changes can be made to the system in light of the above
description. While the above description describes certain examples of the
technology,
and describes the best mode contemplated, no matter how detailed the above
appears in
text, the technology can be practiced in many ways. As noted above, particular
terminology used when describing certain features or aspects of the system
should not be
taken to imply that the terminology is being redefined herein to be restricted
to any
specific characteristics, features, or aspects of the system with which that
terminology is
associated. In general, the terms used in the following claims should not be
construed to
limit the system to the specific examples disclosed in the specification,
unless the above
description section explicitly and restrictively defines such terms.
Accordingly, the actual
scope of the technology encompasses not only the disclosed examples, but also
all
equivalent ways of practicing or implementing the technology under the claims.
[0228] Particular structural characteristics (e.g., cross-sectional shape,
material
composition, etc.) ascribed to components (e.g., frames, rails, joists, posts,
panels, etc.) of
example embodiments described herein are not necessary in all embodiments.
Accordingly, components should not be interpreted as being limited to having
particular
structural characteristics ascribed to them in example embodiments.
[0229] From the foregoing, it will be appreciated that specific examples of
apparatus and
methods have been described herein for purposes of illustration, but that
various
modifications, alterations, additions and permutations may be made without
departing
from the practice of the invention. The embodiments described herein are only
examples.
Those skilled in the art will appreciate that certain features of embodiments
described
herein may be used in combination with features of other embodiments described
herein,
and that embodiments described herein may be practised or implemented without
all of
the features ascribed to them herein. Such variations on described embodiments
that
would be apparent to the skilled addressee, including variations comprising
mixing and
matching of features from different embodiments, are within the scope of this
invention.
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[0230] Alternative embodiments may include the following variations:
= As an alternative or addition to shear connectors, some embodiments may
couple
segments (i.e., frame components such as the corner posts, side rails, end
rails,
etc.) by wrapping them with Fibre Reinforced Polymer (FRP). FRP may include
carbon FRP, glass FRP, and the like.
= Columns, beams, and slabs may be made arbitrarily thick or thin.
= The number of shear connectors shown in the illustrated embodiments is
not
meant to be specific. The quantity, type, size and the like of shear
connectors
required may be specific to a particular column or building and the
illustrated
representation of type and quantity are exemplary only.
= Lengths of column closures and beam soffit members may be varied. For
example, a column closure may span two or more vertically arranged modules.
= Vertically adjacent column closures (e.g., enclosing different portions
of a column
that spans two or more floors of a building) may be joined together, such as
by a
butt weld, lap joint and/or the like, for example.
= Column closures need not have shear connectors.
= Column closures may have shear connectors projecting from both major
sides,
such as for integrating end-wise adjacent modules, for example.
= A single column closure may close two or more sides of a column volume.
For
example, a column closure may comprise an I-beam whose flanges each close an
opposite side of a column volume (e.g., similar to I-beam 772).
= Spacers may be configured for aligning and spacing eight adjacent modules
(i.e.,
four corner-adjacent upper modules and four corner adjacent lower modules).
= Spacers need not engage orifices of corner fittings. For example, spacers
may be
welded to top and/or bottom rails intermediate corners of frames.
= Volumetric construction modules may incorporate parts of intermodal
shipping
containers of various sizes.
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o For example, volumetric construction modules may incorporate parts of
intermodal shipping containers having lengths of 12192 mm (40 feet),
2991 mm (10 feet), 9125 mm (30 feet), 13716 mm (45 feet), 14630 mm
(48 feet), and 17154 mm (53 feet).
o For another example, volumetric construction modules may incorporate
parts of intermodal shipping containers having widths greater than 8 feet.
o For a further example, volumetric construction modules may incorporate
parts of standard height intermodal shipping containers having, which are
2591 mm (8 feet 6 inches) high.
= Columns need not be formed at the ends of modules. For example, where a
module incorporates a 17154 mm (53 foot) intermodal shipping container frame,
structurally strong corner posts will be located approximately 6.5 feet inward
from the ends of the module. Shear connectors may be secured to these corner
posts, and columns that include these shear connectors formed adjacent to the
posts.
= Volumetric construction modules need not incorporate parts of intermodal
shipping containers. Components of intermodal shipping containers used in
descriptions of example embodiments may be substituted with any functionally
equivalent component, feature or combination of components and/or features.
= Volumetric construction modules may comprise corner fittings that, unlike
the
corner fittings of intermodal shipping containers, are fabricated from sheet
steel or
the module may have a corner post perforated for ease of interconnection with
handling equipment or other modules.
= Modules of different dimensions may be integrated in the same building, on
different floors or on the same floor.
= Buildings may comprise modules which differ in one or more of height,
length,
width and orientation.
= Differences in dimension and/or orientation among modules in a building
may be
accommodated by dimensional differences among columns, beam and slabs of the
building.
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= Modules need not have floors and/or top panels.
= Components assembled with example modules in described example
embodiments (e.g., column closure members, beam soffit members, edge slab
closures, spacers, etc.) may be formed, fabricated or otherwise integrated
with the
module (e.g., at the factory, on site but before modules are placed in spaced
adjacent relation, etc.).
= Components assembled with example modules in described example
embodiments may be integrated with one another (e.g., one or more spacers and
one or more slab edge closures may be provided as single unit, column closure
for
enclosing a single column volume may be provided as a single unit, etc.).
= Modules, frames and components may comprise materials other than steel.
Non-
limiting examples of other suitable materials include:
o metals other than steel;
o wood;
o engineered wood composites (e.g., comprising wood fibre and adhesives,
etc.);
o carbon fibre composites;
o plastics; and
o the like.
= Curable materials other than concrete may be introduced into the structural
volumes (e.g., to form composite columns, beams and/or slabs). Examples of
other suitable curable materials include fibre reinforced polymers, magnesia
cement based materials (e.g., concrete made with magnesium silicate cement,
such as Carbon Negative Cement made by Novacem Limited of London, United
Kingdom), and the like. In some embodiments, shear connectors are not used
where high-strength curable materials such as Carbon Fibre Reinforced Polymer
(CFRP) or high strength concrete (e.g. concrete reinforced with steel filings)
are
used and temporary formwork used to encase the segments (i.e., corner posts,
side
rails, etc.) with these curable materials.
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CA 02853511 2015-04-16
" =
= Fire rating material, such as intumescent paint, furring and gypsum board
sprayed
insulation or the like, for example, may be provided to protect the exposed
structural steel
in volumetric construction modules from heat due to fire.
= Volumetric construction modules of the present invention may be adapted
to augment
any building structure to provide pre-manufactured highly finished areas. For
example,
volumetric construction modules containing kitchens and bathrooms may be
stacked floor
by floor and form a portion of the building structure in a high rise
reinforced concrete
building and the modules can be spaced vertically to match the story
elevations floor to
floor.
[0231] While a number of exemplary aspects and embodiments have been discussed
above, those
of skill in the art will recognize certain modifications, permutations,
additions and sub-
combinations thereof. The scope of the claims should not be limited by the
preferred
embodiments set forth in the examples, but should be given the broadest
interpretation consistent
with the description as a whole.
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