Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/174216
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MODULAR CONSTRUCTION INCLUDING FIRE-SUPPRESSING GASKET
RELATED APPLICATION
The present application is a Non-provisional of, and claims
priority under 35 USC 119 from US Provisional Application Serial No.
63/148,331 filed February 11, 2021, the contents of which are incorporated by
reference.
BACKGROUND
The present invention relates generally to modular construction
techniques for erecting multi-story buildings, and more specifically to
improve
intra- connection of modular units "modules" for improving resistance to the
progression of smoke and/or fire between assembled modular units that are
assembled to create the modular building.
It is a growing trend to construct multi-story modular buildings,
including hotels, apartments, dormitories, classrooms, restaurants and the
like
using a variety of modular units in different lengths, widths and heights,
especially in crowded urban areas where heavy construction equipment has
difficulty maneuvering. Modular construction techniques reduce material
waste, and since the units are assembled indoors at remote locations, labor
costs and working conditions are more closely controlled. Such modules are
remotely constructed and assembled, trucked to the building site, then placed
in position using a crane. The modules are assembled by stacking vertically,
side-by-side or end-to-end, thus providing a variety of configurations of the
final building design.
Each module is constructed of a combination of building
components utilizing commonly sourced materials including wood and steel.
The module components are groups and subgroups of various independent
building materials that are combined to create a panel or building element.
The panel or building element includes frames, joists, beams, columns, floor
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cassettes, ceilings and roofs. The panel or building elements are combined
with intersecting connections to eventually form a two to six-sided module. A
single or a series of parallel, adjacent and/or stacked modules make up the
modular building. Modular buildings may be designed as combustible or non-
combustible. A suitable module is described in commonly-owned US Patent
No. 10,066,390 which is incorporated by reference.
In constructing such units, it is customary to place steel support
or load plates at the corners of each unit as they are stacked on top of each
other, so that there is a steel-to steel connection between the plates and the
frames of the vertically-adjacent modules that supports the weight of the
stack
of modules forming the building. Usually, the plates have a thickness or
height of approximately 3/4 inch and a 4-inch X 4-inch periphery. This
assembly procedure creates a gap between the vertically stacked units, which
extends laterally for the entire horizontal width of the structure, as well as
for
the entire length of the structure. Similar, vertically projecting gaps are
also
defined by the placement of laterally adjacent units.
These gaps have a potential for forming smoke or fire
passageways or chimneys that potentially enhance the spread of fire from one
modular unit to another. Accordingly, building codes require that these gaps
are covered at the intersection of modular units on every floor by facing
panels of gypsum wallboard, which as is well known in the art, has fire
retarding properties. In some cases, the gypsum panels are backed with
fiberglass insulation or the like. A drawback of these requirements is the
difficulty in durably attaching relatively thin panels of wallboard to
existing
structures for adequately plugging these gaps. The issue here is that it is
extremely difficult to extend the drywall uninterrupted from the top of wall
through the floor/ceiling concealed space to the underside of the next
adjacent upper deck in modular constructions in order to maintain the wall
fire
rating. The nature of the modules forces a joint in the drywall between the
floor and ceiling assemblies, thereby causing a prohibited fire break. In some
cases, the existing techniques are successful in inhibiting the vertical
progression of smoke or fire, but not as successful in inhibiting lateral
progression.
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Thus, there is a need for an improved construction assembly
and technique for assembling modular building units which inhibits the
progression of smoke and fire between units both vertically and horizontally.
There is also a need for an improved construction assembly and
technique for assembling modular building units which replaces the
conventional techniques of adding thin strips of wallboard for closing the
inter-
module gap.
SUMMARY
The above-listed needs are met or exceeded by the present
gasket for installation between modular construction units. In a preferred
embodiment, the gasket is dimensioned to fill a gap defined between vertically
and horizontally adjacent modular units. As such, the gasket has cutouts or
plate recesses dimensioned to accommodate the conventional support plates
used between modular units. In construction, the present gasket in a
preferred embodiment is a combination of layers of structural cement panel
and mineral wool. Regarding the structural cement panel, all conventional,
cement core, fiber-reinforced panels are contemplated, including Portland
cement and magnesium oxide based panels.
Contemplated gasket combinations include a sandwich of a pair
of panels with mineral wool inserted between the panels. In another
embodiment, the combination includes respective layers of panel and mineral
wool, with either layer facing up and the other facing down as the gasket is
placed between vertically adjacent modular units. Still another contemplated
gasket is a panel layer sandwiched between layers of mineral wool. Other
contemplated gaskets are exclusively layers of structural cement panel or
mineral wool. In embodiments where the gasket includes a combination of
panels and mineral wool, it is preferred that the respective layers are
fastened
to each other with chemical adhesive. In other embodiments, the gasket is
assembled onsite, with one layer placed upon another, in some cases
optionally fastened together with adhesive.
By creating a gasket of noncombustible materials (structural
fiber cement panel and mineral fiber), once the lower modules are placed, the
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support plates are installed, the gasket is put into position, and the top
modules are placed over the top panel of the gasket. When provided, the
mineral wool acts as a compressible sealant. Test fire temperatures for rated
walls and floor/ceiling assemblies customarily reach 2000 C. The mineral
wool melts at higher temperatures, and thus remains intact and is therefore
suitable for the application.
An advantage of the present gasket is that it provides enhanced
strength and durability compared to gypsum wallboard panels, allows for
installation of building modules without sacrificing the integrity of the code-
required fire barrier, while also preventing smoke and fire from travelling up
through the cavity created between the two adjacent, same level modules.
The present gasket prevents the propagation of smoke and fire from the
concealed space of the floor/ceiling assembly from left-to-right (and vice
versa), as well as in the vertically extending space between the double walls
formed when two modules on the same level are placed beside each other.
More specifically, the present invention provides a gasket for
installation in a gap defined by adjacent modular construction units, each
having a support frame. The gasket includes at least one layer of structural
cement panel; and at least one layer of mineral wool, and the at least one
layer of said panel and mineral wool has at least one plate recess configured
for accommodating a support plate.
In another embodiment, a modular building construction is
provided, including a plurality of modular units, each unit having a steel
frame.
Four adjacent units of the plurality form an intersection, and support plates
are
fastened at upper surfaces of corners formed by each frame. A gasket is
disposed in a gap defined at the intersection, the gasket having four plate
recesses for accommodating the support plates. The gasket is constructed
and arranged for insertion into the gap and for blocking passage of smoke
and fire in the gap.
In still another embodiment, a method of constructing a building
made of modular units includes providing a pair of modular units, each having
a steel frame including intersecting beams forming at least one corner, each
corner having a support plate; locating the modular units next to each other;
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providing a gasket that overlaps opposing edges of each modular unit, the
gasket having plate recesses dimensioned for accommodating the support
plates; and installing a supplemental pair of modular units vertically above
the
pair of modular units, the supplemental modular units engaging the support
plates and also compressing the gasket.
In a preferred embodiment, one plate recess is formed at each
of four corners of said panel and said mineral wool. In an embodiment, the
gasket has a length corresponding to a length of the modular construction
unit. Further, the combined panel and mineral wool layers have a height in
the range of 1 3/4 to 3 inches. When the gasket is a single layer of panel or
mineral wool, the thickness is at least 0.5 inch. In an embodiment, the
combined panel and mineral wool layers have a width in the range of 12 to 24
inches in a main portion, excluding the corners.
In an embodiment, the gasket includes an upper panel layer, a
lower panel layer, and a middle layer of the mineral wool. In an embodiment,
the gasket includes an upper mineral wool layer, a lower mineral wool layer,
and a middle layer of the panel. It is further contemplated that the gasket is
made of at least one layer of structural cement panel. It is still further
contemplated that the gasket includes an upper panel layer, a lower panel
layer, and a middle layer of mineral wool. In another embodiment, the gasket
includes an upper mineral wool layer, a lower mineral wool layer, and a
middle layer of said panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a building being made of modular
units "modules" of the type equipped with the present gasket;
FIG. 2 is a fragmentary exploded junction of four modules of the
type illustrated in FIG. 1 showing the disposition of the present gasket;
FIG. 3 is a fragmentary assembled vertical cross-section of four
modules equipped with the present gasket;
FIG. 4 is a fragmentary vertical cross-section of an embodiment
of the present gasket;
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FIG. 5 is a fragmentary vertical cross-section of another
embodiment of the present gasket;
FIG. 6 is a fragmentary vertical cross-section of still another
embodiment of the present gasket; and
FIG. 7 is a fragmentary vertical cross-section of yet another
embodiment of the present gasket.
DETAILED DESCRIPTION
Referring now to FIGs. 1-3, a multi-story building incorporating
the present modules is generally designated 10, and includes a plurality of
joined module units 12. Each module unit 12 includes a plurality of building
elements, panels 14, doors 16 and windows 18. The wall panels 14 are
preferably made of structural cement, according to US Patent Nos. 7,445,738
and 7,670,520 which are incorporated by reference, however other exterior
construction panels are contemplated. As described above, structural cement
panels 14 are also contemplated as including all conventional, cement core,
fiber-reinforced panels, including Portland cement and magnesium oxide-
based panels A ceiling 20 of a lower unit 12L becomes part of a floor 22 of
an upper unit 12U. Naturally, as the building 10 is provided with multiple
stories, an upper module 12U of one floor/ceiling assembly will serve as the
lower module 12L of the next higher story. An intersection of four adjacent
modular units 12 is generally designated 24 (FIG. 3).
Referring now to FIGs. 2 and 3, the intersection 24 is depicted in
greater detail. Each modular unit 12 includes a steel frame 26 including
horizontal beams 28 and vertical studs 30 welded or bolted together to form a
rigid structure to which the wall panels 14, doors 16 and windows 18 are
attached, using threaded fasteners as known in the art. In the preferred
embodiment, the ceiling beams 28 (and columns or posts 30) have a
minimum height (width) of 3 inches, and are preferably 14 MSG grade steel,
however other sizes are contemplated depending on the application. At least
one connector or bearing support plate 32 is secured to a corner 34 of the
frame 26 defined by joined beams 28 at a 90 angle, preferably by welding.
However, other attachment techniques known in the art are contemplated,
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including threaded fasteners and couplings. In the preferred embodiment,
while other sizes are contemplated depending on the application, the
connector plate 32 is preferably a minimum 3A-inch thick or having that size
height, and is provided in a polygonal shape that is preferably dimensioned 4
inches by 4 inches. Also, the connector plate 32 is used to join the upper
unit
12U to the lower unit 12L, again preferably by welding or similar permanent
attachment. This construction enhances the integrity and strength of the
assembled building 10.
A space, gap or cavity 36 is defined between the upper unit 12U
and the lower unit 12L that extends a full length of the units 12, as well as
a
full height of the units, with the exception of the support plates 32. A
gasket
40 is constructed and arranged for filling the space 36 between the upper and
lower modular units 12U, 12L where opposing edges of laterally-spaced
modules are adjacent each other. Preferably, the gasket 40 includes at least
one, and preferably four polygonal plate recesses 42 every 12 feet
dimensioned for accommodating the support plates 32 at each corner 34 of
the frame 26. In the preferred embodiment, the plate recesses 42 are square
in shape, however other configurations are contemplated, depending on the
shape of the support plate 32. As seen in FIG. 2, the plate recesses 42 are
preferably located at corners of the gasket 40, however, in addition, the
recesses are contemplated as being located between ends 43 of the gasket.
The gasket 40 is planar in shape and is constructed and
arranged for filling the space 36 at the intersection 24 between vertically
adjacent modules 12U, 12L, as well as overlapping laterally adjacent modules
to prevent the spread of smoke and/or fire in the space 36. As such, the
gasket 40 has a length "L" corresponding to a length of the modular
construction unit 12. Further, the gasket 40 has a width "W' in the range of
in
the range of 12 to 24 inches in a main portion, excluding the plate recesses
42. Preferably, the gasket 40 is made of fire resistant materials. Further,
the
gasket 40 is constructed to accommodate the compressive forces generated
from the weight of the vertically-stacked modules. Thus, while the gasket 40
has a relatively limited width "W' compared to a width of the modules 12, due
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to the placement of the gasket 40 at the intersection 24, lateral and vertical
migration of smoke and/or fire between modules is prevented.
Referring now to FIG. 4, in an embodiment, the gasket 40 is
made of at least one layer of structural cement panel 44 and at least one
layer
of mineral wool 46. It is preferred that the structural cement panel 44 is of
the
type sold by United States Gypsum Co. as Structural Panel Concrete
Subfloor, also sold under the trademark STRUCTO-CRETE panels, and is
preferably made according to at least one of US Patent Nos. 7,445,738 and
7,670,520. In the preferred embodiment, the panels 44 are a minimum 1/2-
inch thick or tall. The mineral wool layer 46 is made of widely available
material. As seen in FIG. 2, each of the layers 44, 46 has the plate recesses
42 for accommodating the support plates 32.
In an embodiment, when the gasket 40 includes panel and
mineral wool layers 44, 46, the gasket has a height "H" in the range of 1 3/4
to
3 inches. As seen in FIG. 4, one embodiment of the gasket 40 features an
upper panel layer 44a, a lower panel layer 44b, both layers made of structural
cement panels, and a middle layer 46a of mineral wool.
Referring now to FIG. 5, in another embodiment, the gasket 40
is contemplated as included a layer of panel 44a and a layer of mineral wool
46a, or alternately, a layer of panel 44a sandwiched between layers of mineral
wool 46a, 46b. Referring now to FIG. 6, it is further contemplated that the
gasket 40 is made of a single layer of panel 44, or, in FIG. 7, a single layer
of
mineral wool 46.
Referring again to FIGs. 1 and 2, the gasket 40 is shown
installed between adjacent modular units 12 in the construction of the modular
building 10. It is seen that the gasket 40 is positioned along a common edge
48 of the units 12 and overlaps laterally onto each unit. As such, the
disposition of the gasket 40 at the intersection 24 between four modular units
12 prevents both lateral and vertical migration of smoke and/or fire in the
space 36 between the units. The plate recesses 42 accommodate the
support plates 32 at each corner and/or intermediary points of the frames 26
which form each unit 12.
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During construction of the building 10, after placement of a pair
of laterally adjacent modular units 12, the support plates 32 are optionally
fixed in place on the corners and/or intermediary points 34 of the frame 26.
It
is also contemplated that the support plates 32 are installed remotely at a
factory fabricating the units 12. The gasket 40 is installed along the
opposing
edges 48 of the adjacent modular units 12 so that the plate recesses 42 are
located at the support plates 32. Each gasket 40 thus covers the space 36
between the adjacent modular units 12 and also prevents lateral migration of
smoke and/or fire once an additional two supplemental units 12 are placed
above the first two modular units and the gasket 40, and the supplemental
units are secured in place. VVhen multiple layers of the gasket 40 are
provided, the layers of structural cement panel 44 and mineral wool 46 are
preferably fastened together with chemical adhesive at a remote factory, or
are assembled onsite by placing layers upon each other, and optionally
applying chemical adhesive, as by spraying, brushing, rolling or the like as
is
known in the art.
While a particular embodiment of the present modular
construction including a fire-suppressing gasket has been described herein, it
will be appreciated by those skilled in the art that changes and modifications
may be made thereto without departing from the invention in its broader
aspects and as set forth in the following claims.
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