APPARATUS, SYSTEMS AND METHODS FOR
MODULAR CONSTRUCTION
Related Application
This application claims priority to, and incorporates by reference in its entirety, U.S.
provisional application no. 61/570,656 filed 14 December 2011.
Technical Field
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
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.
[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.
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.
), in general this is not cost efficient.
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 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.
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.
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
• US 2007/0084135 – CONSTRUCTION SYSTEM FOR STEEL-FRAME BUIDLINGS
• US 2011/0036018 – MOVABLE BUILDING
• – MODULAR BUILDING CONSTRUCTION UNIT, SYSTEM,
AND METHOD
• – FIRE RATED, MULTI-STOREY, MULTI-DWELLING
STRUCTURE AND METHOD TO CONSTRUCT SAME
• – 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
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.
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 incorporating at least a
portion of the first segment within 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.
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.
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.
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. 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.
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.
The method may comprise prior to step (b): step (a)(i) of providing a second volumetric
construction module comprising a frame, the first and second volumetric construction modules in
lateral relation, wherein at least one of the frames of the first and second volumetric construction
modules comprises the first segment; and step (a)(ii) of 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, at least one of the panel expansion member and the floor frame comprising a second
segment; and wherein step (b) comprises defining a volume of a composite segment
incorporating at least a portion of each of the first segment and the second segment within the
volume. 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 first reinforcement elements may comprise rebar rods and the second reinforcement
elements comprise rebar stirrups.
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.
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 building comprising a frame
comprising a second segment; (c) defining a volume of a composite segment incorporating at
least a portion of each of the first segment and the second segment; and (d) filling the volume
with a curable material to cast the composite segment. 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.
Described herein is 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.
Described herein is 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 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.
Described herein is 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.
Described herein is 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 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.
Described herein is 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 the third corner post section, the fourth
corner post section, and the second plurality of shear connectors.
Described herein is 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.
Described herein is 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 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.
Described herein is 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.
Described herein is 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 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.
Described herein is 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.
Described herein is 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 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.
Described herein is 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 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 incorporating at least a portion of the first segment within the
volume; and a structure adjacent the first volumetric construction module, the adjacent structure
comprising a second segment, wherein the volume integrates at least a portion of each of the first
segment and the second segment; and concrete occupying the volume. 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.
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.
Figure 3 is an isometric view of a volumetric construction module according to an
example embodiment.
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.
Figure 4A is a detail isometric view of an angle member installed on a panel section
shown in Figure 4.
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.
Figure 7A is an opening end elevation view of the volumetric construction module of
Figure 3.
Figure 7B is a closed end elevation view of the volumetric construction module of Figure
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.
Figure 8C is an isometric view of a column reinforcement member according to an
example embodiment.
Figure 9 is an isometric view of a beam soffit member according to an example
embodiment.
Figure 9A is an isometric view of a panel expansion member according to an example
embodiment.
Figure 10 is an isometric view of a spacer according to an example embodiment.
Figure 11 is an isometric view of a slab edge form member according to an example
embodiment.
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.
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.
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.
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.
Figure 18 is a cross-section through a composite beam according to a further example
embodiment.
Figure 19 is a cross-section through a composite beam according to a further example
embodiment.
Figure 20 is a cross-section through a composite beam according to a further example
embodiment.
Figure 21 is an isometric view of a spacer according to an example embodiment.
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.
Figure 23 is a flow chart of a construction method according to an example embodiment.
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.
Figure 25 is an end view cross-section of a portion of the assembly of Figure 24.
Figure 26 is a cross-section through a composite beam according to a further example
embodiment.
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.
Figure 28 is an isometric view of a multi-story building according to an example
embodiment.
Figure 29 is a floor plan of the building shown in Figure 28, shown with modules
removed.
Figure 30 is a floor plan of the building shown in Figure 28 with modules shown.
Figure 31 is a side elevation view of the building core of the building shown in Figure 28.
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.
Figure 34 is a schematic plan view cross-section through a column formed in part by two
laterally adjacent closed end corner posts.
Figure 35 is a schematic plan view cross-section through a column formed in part by two
facing adjacent opening end corner posts.
Figure 36 is a schematic plan view cross-section through a column formed in part by two
laterally adjacent opening end corner posts.
Figure 37 is a schematic plan view cross-section through a column formed in part by one
opening end corner post.
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.
Figure 40 is a schematic plan view cross-section through a column formed in part by one
closed end corner post.
Figure 41 is a schematic plan view cross-section through a shear wall according to an
example embodiment.
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.
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.
Figure 45 is a cross section through a composite beam according to an example
embodiment.
Figure 46 is a cross section through a composite beam according to an example
embodiment.
Figure 47 is a cross section through a composite beam according to an example
embodiment.
Description
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.
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 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.
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
½ 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).
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 modules not having opening and closed ends may be used
in embodiments of the invention.
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.
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
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.
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.
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.
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 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.
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.
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;
• 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.
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.
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.
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 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.
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 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.
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.
Sides 40 of module 100 comprises shear connector arrays 112O and 112C. Shear
connector arrays 112O and 112C each extend between adjacent corners of frame 12. Shear
connector arrays 112O and 112C are adjacent opening end 20 and closed end 30, respectively, of
module 100. In the illustrated embodiment, shear connector arrays 112O and 112C comprise
outwardly projecting shear connectors 110 arrayed on panel sections 128 and 138, respectively.
More particularly, arrays 112O and 112C each comprise a plurality (3) of vertical columns of
spaced apart, laterally-extending headed steel shear studs. In array 112O, 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.
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.
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.
Opening end 20 of module 100 comprises a shear connector array 118O. Shear connector
array 118O comprises outwardly projecting shear connectors 110 adjacent the bottom of first
opening 22A. In the illustrated embodiment, array 118O comprises a single row of spaced apart
headed steel shear studs. The shear studs 110 of array 118O are rigidly connected to opening
end bottom rail 26. In some embodiments, module 100 may not have shear connector array 118O
(e.g., in embodiments where opening end 20 of module 100 forms part of an outward face of a
building).
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 118O and 118C may be referred to interchangeably or
collectively herein as shear connector arrays 118.
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,
• T connectors,
• Hilti™ HVB connectors;
• Hambro™ top cord elements; and
• the like.
A row or column of shear connector arrays 112O, 112C, 114 116 and/or 118 may
comprise as few as one shear connector. For example, in some embodiments, arrays 112O 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 112O, 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.
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.
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, 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.).
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 112O’, 112C’, 114’,
116’, and 118C’ comprises shear bolts instead of headed studs, shear connector arrays 112O’ 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.
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.
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.
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.
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 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.
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
Welding™. Panel member 177 may for example comprise corrugated side wall steel of an
intermodal shipping container.
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.
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.
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 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 150O, 150C, 160O and 160C);
• a beam soffit member 170;
• a plurality of spacers 180 (individually identified in Figure 12 as spacers 180O and
180C); and
• a plurality of slab edge form members 190 (individually identified in Figure 12 as slab
edge form members 190O and 190C).
[0129] For convenience, features of the aforementioned components are identified using the
same reference numerals as in their descriptions.
In assembly 200, column closure members 150O and 160O 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 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 160O 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.
Opening end slab edge form member 190O and opening end spacer 180O 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 180O 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 180O 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.
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 180O and 180C. The ends of beam soffit
member 170 are aligned with column closure members 150O and 150C. Shear connectors 174
of beam soffit member 170 extend through slab volume 260 into beam volume 246.
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:
• column volume 228 is closed on:
o a first side by C-channel beam 162 of column closure member 160O and includes
shear connectors 164 that project therefrom,
o a second side by C-channel beam 152 of column closure member 150O and
includes shear connectors 154 that project therefrom, and
o a third side by panel section 128 and includes shear connectors 110 of array 112O
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.
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 180O 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
• 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.).
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.
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 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.
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.
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.
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.
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.
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.
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.
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 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 112O 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.
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.
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.
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 160DO 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 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 150DO and 160DO, 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.
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.
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 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).
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.
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.
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 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.
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.
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 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.
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 112O, which is visible in Figure
), 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 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.
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.
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.
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 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.
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.
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.
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.
[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.
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’’.
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 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.
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 950O, 950C, 960O 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
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.
In assembly 900, column closure members 950O and 950C are generally perpendicular to
and abut inward edges of panel sections 128 and 138, respectively. Column closure members
960O and 960C are generally parallel to and abut outward edges of panel sections 128 and 138,
respectively. Column closure members 950O and 960O close vertically-extending sides of
opening end column volume 928. In like fashion 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 960O) 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.
Column closure member 960O 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 118O, 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 960O. 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.
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’, 400B’, 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 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.
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.
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 tied to floor frame 62 of module 410C’ by bolts of shear array
118O. 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.
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.
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 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, 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 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.
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.
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’.
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.
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.
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.
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.
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.
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.
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.
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
[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 400’.
[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.
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.
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 1512 of opposing shear connector arrays of corner posts 1510
pass by each other in overlapping fashion.
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.
[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.
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.
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
• 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.
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.
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).
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 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).
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).
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).
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 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.
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.
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.
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.
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.
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.
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
Lenton Quick Wedge or Lenton 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.
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.
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.
Figure 44A is a cross section end view of composite beam 4404.
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 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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
As will be apparent to those skilled in the art in light of the foregoing disclosure, many
alterations and modifications are possible in the practice of this invention without departing from
the spirit or scope thereof. For example:
• 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.
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.
• 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.
• 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.
The term ‘comprising’ as used in this specification and claims means ‘consisting at least
in part of’. When interpreting statements in this specification and claims which include the term
‘comprising’, other features besides the features prefaced by this term in each statement can also
be present. Related terms such as ‘comprise’ and ‘comprised’ are to be interpreted in a similar
manner.
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. It is therefore intended that the following appended claims and claims
hereafter introduced are interpreted to include all such modifications, permutations, additions
and sub-combinations as are within their true spirit and scope.