US20230160196A1 - Modular habitable structures, and associated systems and methods - Google Patents
Modular habitable structures, and associated systems and methods Download PDFInfo
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- US20230160196A1 US20230160196A1 US17/456,264 US202117456264A US2023160196A1 US 20230160196 A1 US20230160196 A1 US 20230160196A1 US 202117456264 A US202117456264 A US 202117456264A US 2023160196 A1 US2023160196 A1 US 2023160196A1
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- module
- rib assemblies
- chord
- shear keys
- positioning
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B1/34815—Elements not integrated in a skeleton
- E04B1/3483—Elements not integrated in a skeleton the supporting structure consisting of metal
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/348—Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
- E04B1/34807—Elements integrated in a skeleton
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
- E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
- E04B1/2403—Connection details of the elongated load-supporting parts
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
- E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
- E04B1/2403—Connection details of the elongated load-supporting parts
- E04B2001/2463—Connections to foundations
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
- E04B1/24—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal
- E04B2001/2466—Details of the elongated load-supporting parts
Definitions
- a module may include a first upper chord oriented along a length of the module, a first lower chord oriented along the length of the module, a second upper chord positioned opposite the first upper chord, parallel to the first upper chord, a second lower chord positioned opposite the first lower chord, parallel to the first lower chord, and a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords.
- At least one of the chords may include a plurality of chord portions joined together with one or more connector plates.
- Two of the rib assemblies may include shear keys configured to be received in support structures, such as piers at a final installation site.
- each chord portion includes a plurality of arrays of holes.
- the rib assemblies may include two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other.
- the shear keys may project downwardly from the vertical column beams.
- Another representative embodiment of the present technology includes a method of making a structure.
- Making the structure may include making a module of the structure.
- the method may be at least partially performed at a first location (such as a factory) that is remote from a second location (such as a final outdoor installation location of the structure).
- the method may include positioning shear keys (attached to the module) into pockets formed in piers (such as concrete piers) at the final installation location.
- the method may include leveling the module by positioning shims in the pockets under the shear keys or moving the shear keys within the pockets. Empty space in the pockets may be filled with filler material, eliminating a need for bolting the module to the piers.
- FIG. 1 illustrates a perspective view of a modular structure configured in accordance with embodiments of the present technology.
- FIG. 2 illustrates a perspective view of a module configured in accordance with embodiments of the present technology and suitable for use in the modular structure shown in FIG. 1 .
- FIG. 3 illustrates a side perspective view of a chord portion configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in FIG. 2 .
- FIG. 4 illustrates a chord configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in FIG. 2 .
- FIG. 5 a illustrates a rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in FIG. 2 .
- FIG. 5 b illustrates another rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in FIG. 2 .
- FIG. 6 illustrates positioning a module on a pier at a final installation site, in accordance with embodiments of the present technology.
- the present technology is directed to modular structures (which may be habitable structures), and associated systems and methods.
- Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to FIGS. 1 - 6 , which illustrate examples of the technology.
- FIG. 1 illustrates a perspective view of a modular structure 100 configured in accordance with embodiments of the present technology.
- the modular structure 100 may be a habitable structure such as a home or an office, or it may be a structure for storage or other non-habitable purposes.
- the modular structure 100 may be supported on a plurality of piers 110 or other suitable support structures.
- the modular structure 100 can include one or more modules 120 .
- FIG. 1 illustrates two modules 120 joined together at an interface 130 .
- Each module 120 includes usable or habitable interior space, and when multiple modules 120 are joined, they may form a combined interior space.
- Supporting the modules 120 on piers 110 enables building the modular structure 100 on uneven terrain while controlling (e.g., minimizing) the impact on the surrounding environment.
- Supporting the modules 120 on piers 110 may also facilitate using the space beneath the modular structure 100 for storage, additional usable space, or other uses.
- the piers 110 provide elevation above floodwaters.
- modules 120 may be positioned or arranged to form other shapes or configurations of modular structures 100 (i.e., any arrangement or quantity of modules 120 abutting or connected to each other).
- FIG. 2 illustrates a perspective view of a module 120 configured in accordance with embodiments of the present technology and suitable for use in the modular structure 100 shown in FIG. 1 .
- the module 120 may be rectilinear, with rectilinear components.
- the module 120 may include a Vierendeel truss structure.
- four piers 110 may support the module 120 .
- the piers 110 may be positioned approximately 12 feet from ends of the module 120 along the length L of the module 120 , and the piers 110 may be positioned approximately 48 feet apart along the length L of the module 120 , such that the overall module 120 may be approximately 72 feet long.
- the piers 110 may be positioned approximately 18 feet apart along the width W of the module 120 , such that the overall module 120 may be approximately 18 feet in width.
- Other embodiments may include other suitable dimensions, other quantities of piers 110 , or other support structures.
- the module 120 may include a plurality of chords 200 (such as four chords 200 ), which may span the length L of the module 120 .
- the chords 200 may include a first upper chord 202 oriented along the length L of the module, a first lower chord 204 oriented along the length L of the module, a second upper chord 206 positioned opposite the first upper chord 202 and oriented parallel to the first upper chord 202 , and a second lower chord 208 positioned opposite the first lower chord 204 and oriented parallel to the first lower chord 204 .
- the module 120 may also include a plurality of rib assemblies 210 , each of which extends along the width W of the module 120 between the chords 200 .
- the module 120 may further include suitable roof panels 220 and floor panels 230 .
- the roof panels 220 and the floor panels 230 may be supported by the rib assemblies 210 and/or the chords 200 .
- FIG. 2 shows two roof panels 220 and two floor panels 230 , although more or fewer roof panels 220 and/or floor panels 230 may be included in the module 120 .
- the entirety of the top of the module 120 may include roof panels 220
- the entirety of the bottom of the module 120 may include floor panels 230 .
- the module 120 may also include one or more walls or windows 240 , which may also be supported by the rib assemblies 210 and the chords 200 .
- chords 200 may be formed as a single integral beam or with a plurality of chord portions 250 joined together with one or more connector plates 260 .
- FIG. 3 illustrates a side perspective view of a chord portion 250 configured in accordance with embodiments of the present technology and suitable for implementation in the module 120 .
- the chord portion 250 may be an I-beam, a C-beam, a box beam, or another suitable linear extrusion.
- FIG. 4 illustrates a perspective view of a chord 200 configured in accordance with embodiments of the present technology.
- the chord 200 may include two or more chord portions 250 a , 250 b joined together with a connector plate 260 .
- the chord portion 250 may include fastening interfaces in the form of holes 300 that are arranged in arrays 310 (only some of the holes 300 are labeled in FIGS. 3 and 4 to avoid obscuring the figures).
- the connector plate 260 includes one or more arrays 310 of holes 300 corresponding to one of the arrays of holes on a first chord portion 250 a and one of the arrays of holes on a second chord portion 250 b .
- Suitable fasteners 320 such as bolts, may be installed in corresponding holes 300 to hold the chord portions 250 together with the connector plate 260 .
- the connector plate 260 carries the load from one chord portion 250 a to the other chord portion 250 b .
- a connector plate 260 is shown and described for connecting the chord portions 250
- a beam with holes similar to the holes 300 in the connector plate 260 may be used to join the chord portions 250 .
- an overall length L 1 of one or more chord portions 250 may be approximately 405 inches, or other suitable dimensions.
- FIG. 5 a illustrates a bottom perspective view of a rib assembly 500 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies 210 described above with regard to FIG. 2 .
- the rib assembly 500 is a rectilinear structure that includes two vertical column beams 510 each forming a side of the rib assembly 500 , and two or more horizontal crossbeams 520 connecting the column beams 510 to each other, such as one or more upper horizontal crossbeams 520 a and one or more lower horizontal crossbeams 520 b .
- each horizontal crossbeam 520 may be bolted to each column beam 510 .
- the horizontal crossbeams 520 may be welded to the column beams 510 , or they may be attached in other suitable ways.
- the rib assembly 500 may include two upper horizontal crossbeams 520 a connected with one or more upper tie plates 525 , and two lower horizontal crossbeams 520 b connected with one or more lower tie plates 527 .
- the upper and lower tie plates 525 , 527 enhance the squareness and rigidity of the rib assembly 500 .
- the rib assembly 500 may include one or more shear keys 530 (such as two shear keys 530 , or one on each side of the rib assembly 500 ).
- the shear keys 530 may be bolted and/or welded into the rib assembly 500 .
- the shear keys 530 project downwardly from the rib assembly 500 and are configured to engage the piers 110 (see FIGS. 1 and 2 ), as explained in additional detail below with regard to FIG. 6 .
- FIG. 5 b illustrates a rib assembly 540 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies 210 described above with regard to FIG. 2 .
- the rib assembly 540 may be identical to, or generally similar to, the rib assembly 500 described above with regard to FIG. 5 a , except that it may not include the shear keys 530 .
- Each of the rib assemblies 210 , 500 , 540 may be attached to the chords 200 or chord portions 250 via suitable fasteners (such as bolts, screws, or other suitable fasteners) or via welding, or via another suitable attachment.
- a module 120 may be supported on only four piers 110 (or another suitable number of piers 110 ).
- a module 120 may include a number of shear keys 530 corresponding to the number of piers 110 (for example, four shear keys 530 for four piers 110 ).
- a module 120 may include two of the rib assemblies 500 with shear keys 530 , with the remainder of the rib assemblies 210 being the rib assemblies 540 (without shear keys 530 ).
- the rib assemblies 210 , 500 , 540 may include more or fewer features or may take other forms, in other embodiments.
- the module 120 may further include finishing elements that make it more habitable, such as plumbing, electrical facilities, interior bulkheads or walls to create room spaces, and other finishing elements.
- finishing aspects such as flooring, roofing, windows, doors, wiring, plumbing, furnishings, or other aspects may be added to the module 120 in a factory or other site remote from the final installation site.
- the module 120 may be moved to a final installation site as a skeletal frame, and finishing aspects may be added at the final installation site.
- Beams and columns forming the module 120 may be formed with any suitable material, such as steel, aluminum, or another suitable metal material.
- FIG. 6 illustrates positioning a module 120 on a pier 110 at a final installation site, in accordance with embodiments of the present technology.
- the piers 110 may be concrete, and therefore may be subject to their own inaccuracies in location. Embodiments of the present technology compensate for the high tolerances associated with the piers 110 .
- each pier 110 may include a pocket 600 for receiving a shear key 530 .
- the pocket 600 may be wider than the shear key 530 to facilitate adjustment of the position of the module 120 at the installation site (e.g., by moving the shear keys 530 within the pockets 600 ).
- the system may include a shim 610 positioned between the shear key 530 and the bottom 620 of the pocket 600 .
- the shim 610 facilitates leveling and height adjustment to compensate for inaccuracies and/or high tolerances in the pier 110 and/or the pocket 600 .
- shims 610 may not be needed if the piers 110 and pockets 600 are positioned with sufficient accuracy, in some embodiments, shims 610 of different sizes may be used in each pier 110 .
- filler material such as concrete and/or grout material
- all the empty space surrounding the shear key 530 within the pocket 600 may be filled with filler material. Accordingly, in some embodiments, anchor bolts are not needed to mount the module 120 to the piers 110 .
- a method of making a modular structure in accordance with embodiments of the present technology may include building the chords 200 (such as the chords 202 , 204 , 206 , 208 ) and the rib assemblies 210 , then connecting the elements together, then moving the assembly to a final installation site, and then penetrating/positioning the shear keys 530 into the piers 110 .
- the method may include leveling the module 120 using one or more shims 610 and adjusting the position of the module 120 by moving the module 120 relative to the piers 110 (which may include moving the shear keys 530 side to side within the pockets 600 ).
- other/additional modules 120 may be positioned adjacent to the module 120 on their own piers 110 .
- the modules 120 may be positioned and aligned relative to one another, facilitated by moving the shear keys 530 in the open space of the pocket 600 and/or by positioning one or more shims 610 under the shear keys 530 in the pockets 600 .
- methods may include filling the open space in the pockets 600 with grout, concrete, or other suitable filler material to lock modules 120 in position.
- Other finishing work may be performed at any suitable time, such as attachment or installation of components that render the module 120 habitable, including flooring, roofing, electrical, plumbing, and other components.
- part of the assembly process may be performed in a factory, including some of finishing work, such as attaching roof or floor panels, electric, plumbing, etc.
- the modular nature of the assemblies facilitates repeatable and easily duplicated manufacturing and installation of these components.
- embodiments of the present technology provide several advantages. For example, embodiments of the present technology provide known repeatable structures, which enables subsequent finishing trades like mechanical, plumbing, glazing, trim, electrical, etc. to rapidly add their parts with less custom fabrication.
- construction of modules 120 configured in accordance with embodiments of the present technology may not involve any welding at the final installation site (all welding may be performed at the prefabrication site/factory).
- modules 120 and modular structures 100 configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein.
Abstract
A module for a structural system may include chords oriented along a length of the module and a plurality of rib assemblies positioned between the chords. Two of the rib assemblies may include shear keys configured to be received in piers at a final installation site. A method of making a structure may include positioning the shear keys in pockets of the piers.
Description
- Conventional building construction typically involves site-specific designs that are constructed entirely or nearly entirely on-site. There is a desire for modular building designs that can be assembled at a remote site and brought to a building site for assembly in various configurations that can be repeated or altered among various sites.
- Representative embodiments of the present technology include a structural system including one or more modules. A module may include a first upper chord oriented along a length of the module, a first lower chord oriented along the length of the module, a second upper chord positioned opposite the first upper chord, parallel to the first upper chord, a second lower chord positioned opposite the first lower chord, parallel to the first lower chord, and a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords. At least one of the chords may include a plurality of chord portions joined together with one or more connector plates. Two of the rib assemblies may include shear keys configured to be received in support structures, such as piers at a final installation site. In some embodiments, each chord portion includes a plurality of arrays of holes. The rib assemblies may include two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other. The shear keys may project downwardly from the vertical column beams.
- Another representative embodiment of the present technology includes a method of making a structure. Making the structure may include making a module of the structure. The method may be at least partially performed at a first location (such as a factory) that is remote from a second location (such as a final outdoor installation location of the structure). The method may include positioning shear keys (attached to the module) into pockets formed in piers (such as concrete piers) at the final installation location. The method may include leveling the module by positioning shims in the pockets under the shear keys or moving the shear keys within the pockets. Empty space in the pockets may be filled with filler material, eliminating a need for bolting the module to the piers.
- Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.
- In the drawings, wherein the same reference number indicates the same element throughout the several views:
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FIG. 1 illustrates a perspective view of a modular structure configured in accordance with embodiments of the present technology. -
FIG. 2 illustrates a perspective view of a module configured in accordance with embodiments of the present technology and suitable for use in the modular structure shown inFIG. 1 . -
FIG. 3 illustrates a side perspective view of a chord portion configured in accordance with embodiments of the present technology and suitable for implementation in the module shown inFIG. 2 . -
FIG. 4 illustrates a chord configured in accordance with embodiments of the present technology and suitable for implementation in the module shown inFIG. 2 . -
FIG. 5 a illustrates a rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown inFIG. 2 . -
FIG. 5 b illustrates another rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown inFIG. 2 . -
FIG. 6 illustrates positioning a module on a pier at a final installation site, in accordance with embodiments of the present technology. - The present technology is directed to modular structures (which may be habitable structures), and associated systems and methods. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to
FIGS. 1-6 , which illustrate examples of the technology. - The terminology used in this description is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.
- Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components.
- As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms.
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FIG. 1 illustrates a perspective view of amodular structure 100 configured in accordance with embodiments of the present technology. Themodular structure 100 may be a habitable structure such as a home or an office, or it may be a structure for storage or other non-habitable purposes. Themodular structure 100 may be supported on a plurality ofpiers 110 or other suitable support structures. In some embodiments, themodular structure 100 can include one ormore modules 120.FIG. 1 illustrates twomodules 120 joined together at aninterface 130. - Each
module 120 includes usable or habitable interior space, and whenmultiple modules 120 are joined, they may form a combined interior space. Supporting themodules 120 onpiers 110 enables building themodular structure 100 on uneven terrain while controlling (e.g., minimizing) the impact on the surrounding environment. Supporting themodules 120 onpiers 110 may also facilitate using the space beneath themodular structure 100 for storage, additional usable space, or other uses. In coastal areas or other areas prone to flooding, thepiers 110 provide elevation above floodwaters. AlthoughFIG. 1 shows one example ofmodules 120 positioned adjacent to each other to form themodular structure 100, in other embodiments, themodules 120 may be positioned or arranged to form other shapes or configurations of modular structures 100 (i.e., any arrangement or quantity ofmodules 120 abutting or connected to each other). -
FIG. 2 illustrates a perspective view of amodule 120 configured in accordance with embodiments of the present technology and suitable for use in themodular structure 100 shown inFIG. 1 . In some embodiments, themodule 120 may be rectilinear, with rectilinear components. For example, in some embodiments, themodule 120 may include a Vierendeel truss structure. In some embodiments, fourpiers 110 may support themodule 120. In some embodiments, thepiers 110 may be positioned approximately 12 feet from ends of themodule 120 along the length L of themodule 120, and thepiers 110 may be positioned approximately 48 feet apart along the length L of themodule 120, such that theoverall module 120 may be approximately 72 feet long. Thepiers 110 may be positioned approximately 18 feet apart along the width W of themodule 120, such that theoverall module 120 may be approximately 18 feet in width. Other embodiments may include other suitable dimensions, other quantities ofpiers 110, or other support structures. - The
module 120 may include a plurality of chords 200 (such as four chords 200), which may span the length L of themodule 120. For example, in some embodiments, thechords 200 may include a first upper chord 202 oriented along the length L of the module, a first lower chord 204 oriented along the length L of the module, a second upper chord 206 positioned opposite the first upper chord 202 and oriented parallel to the first upper chord 202, and a second lower chord 208 positioned opposite the first lower chord 204 and oriented parallel to the first lower chord 204. - The
module 120 may also include a plurality ofrib assemblies 210, each of which extends along the width W of themodule 120 between thechords 200. Themodule 120 may further includesuitable roof panels 220 andfloor panels 230. Theroof panels 220 and thefloor panels 230 may be supported by therib assemblies 210 and/or thechords 200.FIG. 2 shows tworoof panels 220 and twofloor panels 230, although more orfewer roof panels 220 and/orfloor panels 230 may be included in themodule 120. For example, the entirety of the top of themodule 120 may includeroof panels 220, and the entirety of the bottom of themodule 120 may includefloor panels 230. Themodule 120 may also include one or more walls orwindows 240, which may also be supported by therib assemblies 210 and thechords 200. - One or more of the
chords 200 may be formed as a single integral beam or with a plurality ofchord portions 250 joined together with one ormore connector plates 260. For example,FIG. 3 illustrates a side perspective view of achord portion 250 configured in accordance with embodiments of the present technology and suitable for implementation in themodule 120. Thechord portion 250 may be an I-beam, a C-beam, a box beam, or another suitable linear extrusion.FIG. 4 illustrates a perspective view of achord 200 configured in accordance with embodiments of the present technology. Thechord 200 may include two or more chord portions 250 a, 250 b joined together with aconnector plate 260. - Referring to
FIGS. 3 and 4 , thechord portion 250 may include fastening interfaces in the form ofholes 300 that are arranged in arrays 310 (only some of theholes 300 are labeled inFIGS. 3 and 4 to avoid obscuring the figures). Theconnector plate 260 includes one ormore arrays 310 ofholes 300 corresponding to one of the arrays of holes on a first chord portion 250 a and one of the arrays of holes on a second chord portion 250 b.Suitable fasteners 320, such as bolts, may be installed in correspondingholes 300 to hold thechord portions 250 together with theconnector plate 260. - In some embodiments, the
connector plate 260 carries the load from one chord portion 250 a to the other chord portion 250 b. Although aconnector plate 260 is shown and described for connecting thechord portions 250, in some embodiments, a beam with holes similar to theholes 300 in theconnector plate 260 may be used to join thechord portions 250. In some embodiments, an overall length L1 of one ormore chord portions 250 may be approximately 405 inches, or other suitable dimensions. -
FIG. 5 a illustrates a bottom perspective view of arib assembly 500 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of therib assemblies 210 described above with regard toFIG. 2 . In some embodiments, therib assembly 500 is a rectilinear structure that includes two vertical column beams 510 each forming a side of therib assembly 500, and two or more horizontal crossbeams 520 connecting the column beams 510 to each other, such as one or more upper horizontal crossbeams 520 a and one or more lower horizontal crossbeams 520 b. In some embodiments, each horizontal crossbeam 520 may be bolted to eachcolumn beam 510. In other embodiments, the horizontal crossbeams 520 may be welded to the column beams 510, or they may be attached in other suitable ways. In some embodiments, therib assembly 500 may include two upper horizontal crossbeams 520 a connected with one or moreupper tie plates 525, and two lower horizontal crossbeams 520 b connected with one or morelower tie plates 527. The upper andlower tie plates rib assembly 500. - In some embodiments, the
rib assembly 500 may include one or more shear keys 530 (such as twoshear keys 530, or one on each side of the rib assembly 500). Theshear keys 530 may be bolted and/or welded into therib assembly 500. Theshear keys 530 project downwardly from therib assembly 500 and are configured to engage the piers 110 (seeFIGS. 1 and 2 ), as explained in additional detail below with regard toFIG. 6 . -
FIG. 5 b illustrates arib assembly 540 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of therib assemblies 210 described above with regard toFIG. 2 . Therib assembly 540 may be identical to, or generally similar to, therib assembly 500 described above with regard toFIG. 5 a , except that it may not include theshear keys 530. Each of therib assemblies chords 200 orchord portions 250 via suitable fasteners (such as bolts, screws, or other suitable fasteners) or via welding, or via another suitable attachment. - With additional reference to
FIG. 2 , in some embodiments, amodule 120 may be supported on only four piers 110 (or another suitable number of piers 110). Amodule 120 may include a number ofshear keys 530 corresponding to the number of piers 110 (for example, fourshear keys 530 for four piers 110). Accordingly, in some embodiments, amodule 120 may include two of therib assemblies 500 withshear keys 530, with the remainder of therib assemblies 210 being the rib assemblies 540 (without shear keys 530). Therib assemblies - With continued reference to
FIG. 2 , themodule 120 may further include finishing elements that make it more habitable, such as plumbing, electrical facilities, interior bulkheads or walls to create room spaces, and other finishing elements. In some embodiments, finishing aspects such as flooring, roofing, windows, doors, wiring, plumbing, furnishings, or other aspects may be added to themodule 120 in a factory or other site remote from the final installation site. In other embodiments, themodule 120 may be moved to a final installation site as a skeletal frame, and finishing aspects may be added at the final installation site. Beams and columns forming themodule 120 may be formed with any suitable material, such as steel, aluminum, or another suitable metal material. -
FIG. 6 illustrates positioning amodule 120 on apier 110 at a final installation site, in accordance with embodiments of the present technology. Thepiers 110 may be concrete, and therefore may be subject to their own inaccuracies in location. Embodiments of the present technology compensate for the high tolerances associated with thepiers 110. For example, in some embodiments, eachpier 110 may include apocket 600 for receiving ashear key 530. In some embodiments, thepocket 600 may be wider than theshear key 530 to facilitate adjustment of the position of themodule 120 at the installation site (e.g., by moving theshear keys 530 within the pockets 600). - In some embodiments, the system may include a
shim 610 positioned between theshear key 530 and thebottom 620 of thepocket 600. Theshim 610 facilitates leveling and height adjustment to compensate for inaccuracies and/or high tolerances in thepier 110 and/or thepocket 600. Althoughshims 610 may not be needed if thepiers 110 andpockets 600 are positioned with sufficient accuracy, in some embodiments,shims 610 of different sizes may be used in eachpier 110. When themodule 120 is positioned and leveled at the final installation site, filler material (such as concrete and/or grout material) may be positioned in any empty space surrounding or adjacent to theshear key 530 within thepocket 600. In some embodiments, all the empty space surrounding theshear key 530 within thepocket 600 may be filled with filler material. Accordingly, in some embodiments, anchor bolts are not needed to mount themodule 120 to thepiers 110. - A method of making a modular structure in accordance with embodiments of the present technology may include building the chords 200 (such as the chords 202, 204, 206, 208) and the
rib assemblies 210, then connecting the elements together, then moving the assembly to a final installation site, and then penetrating/positioning theshear keys 530 into thepiers 110. Optionally, the method may include leveling themodule 120 using one ormore shims 610 and adjusting the position of themodule 120 by moving themodule 120 relative to the piers 110 (which may include moving theshear keys 530 side to side within the pockets 600). - Optionally, in some embodiments, other/
additional modules 120 may be positioned adjacent to themodule 120 on theirown piers 110. Themodules 120 may be positioned and aligned relative to one another, facilitated by moving theshear keys 530 in the open space of thepocket 600 and/or by positioning one ormore shims 610 under theshear keys 530 in thepockets 600. In some embodiments, methods may include filling the open space in thepockets 600 with grout, concrete, or other suitable filler material to lockmodules 120 in position. Other finishing work may be performed at any suitable time, such as attachment or installation of components that render themodule 120 habitable, including flooring, roofing, electrical, plumbing, and other components. In some embodiments, part of the assembly process may be performed in a factory, including some of finishing work, such as attaching roof or floor panels, electric, plumbing, etc. The modular nature of the assemblies facilitates repeatable and easily duplicated manufacturing and installation of these components. - Aspects of the embodiments of the present technology provide several advantages. For example, embodiments of the present technology provide known repeatable structures, which enables subsequent finishing trades like mechanical, plumbing, glazing, trim, electrical, etc. to rapidly add their parts with less custom fabrication. In some embodiments, construction of
modules 120 configured in accordance with embodiments of the present technology may not involve any welding at the final installation site (all welding may be performed at the prefabrication site/factory). - From the foregoing, it will be appreciated that specific embodiments of the presently disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the technology. For example, steps of the methods described herein may be performed in different orders or at different times, or concurrently. Accordingly,
modules 120 andmodular structures 100 configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein. - Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the presently disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.
Claims (11)
1. A structural system comprising a module, the module comprising:
a first upper chord oriented along a length of the module;
a first lower chord oriented along the length of the module;
a second upper chord positioned opposite the first upper chord, parallel to the first upper chord;
a second lower chord positioned opposite the first lower chord, parallel to the first lower chord; and
a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords; wherein
at least one of the chords comprises a plurality of chord portions joined together with one or more connector plates; and wherein
two rib assemblies of the plurality of rib assemblies each comprises two shear keys configured to be received in support structures.
2. The system of claim 1 , wherein each of the rib assemblies comprises two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other.
3. The system of claim 2 , wherein the shear keys are attached to the vertical column beams of the two rib assemblies, wherein the shear keys project downwardly from the vertical column beams of the two rib assemblies.
4. The system of claim 1 , wherein the support structures comprise four concrete piers, wherein the shear keys are positioned in the concrete piers.
5. The system of claim 1 , wherein the module is a first module, and wherein the system comprises a second module joined to the first module at an interface.
6. The system of claim 1 , wherein the module is a Vierendeel truss structure.
7. The system of claim 1 , wherein the module further comprises roof panels and floor panels supported by the plurality of rib assemblies or by the chords.
8. A method of making a structure, the method comprising:
at a first location, making a module of the structure, wherein making the module comprises attaching a plurality of rib assemblies to a plurality of chords, wherein attaching the plurality of rib assemblies comprises attaching the rib assemblies perpendicular to the chords, and wherein two rib assemblies of the plurality of rib assemblies each comprise two shear keys configured to be received in support structures at a second location that is different from the first location;
transporting the module to the second location;
at the second location, building a plurality of concrete piers, wherein building the concrete piers comprises forming a pocket in each of the concrete piers; and
at the second location, positioning the module on the concrete piers, wherein positioning the module on the concrete piers comprises positioning the shear keys in the pockets.
9. The method of claim 8 , further comprising attaching roof and floor panels to the module at the first location.
10. The method of claim 8 , further comprising:
positioning a shim beneath one or more of the shear keys within the pocket to level the module; and
after positioning the shear keys in the pockets, positioning a filler material in empty space adjacent to the shear keys within the pockets.
11. The method of claim 8 , wherein the module is a first module, the method further comprising making a second module and positioning the second module adjacent to the first module and leveling the second module relative to the first module.
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US17/456,264 US20230160196A1 (en) | 2021-11-23 | 2021-11-23 | Modular habitable structures, and associated systems and methods |
PCT/US2022/080082 WO2023097163A1 (en) | 2021-11-23 | 2022-11-17 | Modular habitable structures, and associated systems and methods |
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US17/456,264 US20230160196A1 (en) | 2021-11-23 | 2021-11-23 | Modular habitable structures, and associated systems and methods |
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