US3830025A - Building modules - Google Patents

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US3830025A
US3830025A US00265957A US26595772A US3830025A US 3830025 A US3830025 A US 3830025A US 00265957 A US00265957 A US 00265957A US 26595772 A US26595772 A US 26595772A US 3830025 A US3830025 A US 3830025A
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modules
side walls
module
base portions
building
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H Wainshal
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures 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
    • E04B1/34815Elements not integrated in a skeleton
    • E04B1/34823Elements not integrated in a skeleton the supporting structure consisting of concrete

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  • each module generally 5 being comprised of a unitarily formed, steel reinforced, poured concrete roof portion and side walls [56] References Cited extending the length of the roof, the opposed ends thereof being open. A steel reinforced concrete floor UNITED ATE PATENTS slab is formed in 'a.
  • One module may be used individually or two or more FOREIGN PATENTS OR APPLICATIONS modules may be arranged in various stacked and/or 2 006 874 9/1970 6 52,79 side-by-side and spaced-apart arrangements.
  • the present invention pretains to building modules of steel reinforced, poured concrete construction which may, for instance, be used individually as a relatively small apartment sized home or, with no basic modifications, can be stacked and/or placed side-by-side to provide relatively large multi-bedroom single or multifamily residences.
  • Each module is sized for over-the-road transportation and is provided with book means for engagement by appropriate crane means to permit ready movement thereof such as for loading onto and off of the bed of a tractor-trailer truck.
  • the roof and side walls of each module are unitarily formed of steel reinforced, poured concrete and the floor slab is individually, similarly formed and moved into its permanent position between the walls and securely fixed in place by bolt means passed through the side walls into threaded engagement with nut means cast into the floor slab.
  • the assembled roof, side walls and floor form an elongated, open ended generally tubular or tunnel configurated structure.
  • the ends are then provided with closures which are preferably some type of glass enclosure such as glass sliding doors or an entry door in combination with various types of fixed and openable windows.
  • closures which are preferably some type of glass enclosure such as glass sliding doors or an entry door in combination with various types of fixed and openable windows.
  • Various interior arrangements are provided in the modules. For instance, when a module or two or more modules in combination are to be used as a private residence or multiple residence, various room arrangements are provided in each module to form a floor plan quite similar to a conventionally constructed home.
  • each module is sized to accommodate two rooms, one adjacent each end thereof, and various combinations of bathrooms, kitchens, closets and stairways, for two story arrangements, inbetween the two rooms.
  • side wall windows are generally not necessary, However, any side wall or roof openings that are required for side-by-side or up-and-down installations to accommodate doorways, stairs or the like are provided for by properly positioning forms in the main form before pouring the concrete. Side windows, if desired, may also be accommodated in the same manner.
  • Anchor means are provided to anchor ground level modules to the footings or foundations and to anchor the various arrangements of multiple, stacked and/or sideby-side modules together.
  • the modules of the present invention provide a great deal of flexibility and may be used for purposes other than private residences such as for apartment or office buildings.
  • FIG. 1 is a schematic perspective view of a module roof and side wall structure in accordance with the present inventon and a floor slab positioned to be moved into place between the side walls thereof;
  • FIG. 2 is a vertical cross sectional view through a typical modular assembly of this invention
  • FIG. 3 is an enlarged detailed view of the area within the curved line 3--3 of FIG. 2;
  • FIG. 4 is a longitudinal sectional view taken along the line 4-4 of FIG. 3;
  • FIG. 5 is a front elevational view of a pair of modules in a stacked relation
  • FIG. 6 is a schematic illustration of four modules in a side-by-side and a stacked relationship
  • FIG. 7 is a view similar to FIG. 6 illustrating two spaced apart ground level modules and three second story modules thereatop with the center module spanning the space between the two ground level modules;
  • FIG. 8 is an enlarged detail of the area within the curved line 8-8 of FIG. 6;
  • FIG. 9 is an enlarged detail of the area within the curved line 99 of FIG. 6;
  • FIG. 10 is an enlarged detail of the area within the curved line l010 of FIG. 7;
  • FIG. 11 is an enlarged sectional view of the area within the curved line lll1 of FIG. 6.
  • the numeral 10 genrally designates an elongated, generally tunnel shaped structure comprised of a roof l2 and opposed side walls 14 and 16 in accordance with the present invention.
  • Numeral 18 generally indicates a floor slab, positioned to be moved into its proper position between the side walls 14 and 16.
  • the tunnel structure is cast of steel reinforced poured concrete in forms, accurately positioned relative to a pair of rails 20 and 22 which are traversed by a flat-bed truck means 24.
  • the flat-bed truck is provided with wheels 26 which are adapted to ride in the rails 20 and 22.
  • the floor slab 18 is formed and cast of poured concrete on the fiat-bed truck at a location removed from the tunnel structure forming area and when the concrete of both structures has set sufficiently, the forms are removed and the floor slab is moved along the tracks 20, 22 on the flat-bed truck, comprising the bottom form for the slab, into position between the side walls 14 and 16.
  • the tunnel structure form, the rails 20 and 22, the size and height of the flatbed truck are prearranged whereby the base slab 18 is properly positioned between the side walls 14 and 16 to be permanently attached therebetween in the following manner.
  • a plurality of nut means 28 are cast in predetermined spaced positions within and along both edge portions 30 of the concrete floor slab 18.
  • Appropriate through apertures 32 are provided in the lower portions of the side walls 14 and 16 in alignment with the respective nut means 28 cast within the floor slab 18.
  • bolt means 34 are passed through the apertures 32 into threaded engagement with the respective nut means 28 to fix the floor slab 18 in its permanent position relative to the side walls 14 and 16 of the tunnel shaped structure 10.
  • each side edge portion of the floor slab 18 is provided with a plurality of longitudinally extending steel reinforcing rods.
  • four relatively heavy rods 36, 38, 40 and 42 are positioned within each edge portion in a vertically and horizontally spaced relation to form a generally rectangular cross sectional relationship and the four rods 36, 38, 40 and 42 are wrapped along their lengths by a relatively light weight steel wire 44.
  • the assembly of rods 36, 38, 40 and 42 and the wire wrapping 44 are supported along the respective distal end portions 48 of a plurality of spaced-apart transverse slab reinforcing rods 50 and are preferably fixed to the lower rods 40 and 42 by wires or spot-welding.
  • the transverse rods 50 cooperate with a plurality of spaced-apart, longitudinally extending reinforcing rods 52, FIG. 2, to form a generally conventional, waffie form of steel rod reinforcement for the main body portion of the concrete slab 18.
  • Each nut means 28 is formed as a coil of a relatively heavy gauge steel wire 54 and includes an inwardly extending loop 56 having a pair of leg portions 58 and 60 fixed in a horizontal relation as by welding along the diametrically opposed, outer sides of the coil 54.
  • the inner or loop end 62 is supported by the outermost longitudinal reinforcing rod 52.
  • the concrete slab 18 is formed slightly narrower than the inner width between the side walls 14 and 16 to provide a clearance 63 therebetween on each side.
  • Opposed longitudinal grooves 64 and 66 are formed respectively in each longitudinal edge of the slab l8 and its adjacent side walls 14 and 16 in general alignment with the nut means 28 and the through apertures 32.
  • each through aperture 32 includes an enlarged outer portion 68 forming a shoulder 70 to seat an enlarged washer 72 fitted about the bolt means 34.
  • Each bolt means 34 is comprised of a headed bolt and a shank portion having threads 74 configurated for mating reception by the steel coil bolt means 32.
  • the through apertures 32 are filled with an appropriate grout material 76 prior to threading the botls 34 into the nuts 28 and the enlarged outer portions 68 thereof are filled with grout 78, after installation of the bolts 34, to cover the bolt heads.
  • the spaces 62 between the slab edges and the inner surfaces of the side walls 14 and 16 as well as the opposed longitudinal grooves 64 and 66 are likewise filled with an appropriate grout material as illustrated at 80.
  • the grouted grooves 64 and 66 form key means to support the slab 18, relative to the side walls 14 and 16, along the lengths of both side edges thereof.
  • Both side walls 14 and 16 are reinforced by a plurality of vertically and horizontally extending steel rods 82 and 84, generally forming a waffle type network of reinforcing rods.
  • a pair of relatively heavy, longitudinally extending reinforcing rods 86 are preferably provided along each side wall in spanning relation to the bolt means 34.
  • a similar heavy rod 88 may be provided along the lower ends of the vertical rods 82.
  • the inner longitudinal corners between the roof edges 90 and 92 and the respective side walls are rounded or coved as illustrated at 94 and 96 and additional steel reinforcing, as generally indicated at 97 in FIG. 2, is provided to add additional strength thereto.
  • loop means 98 extend upwardly and outwardly from the roof.
  • the loop means generally comprise a pair of steel loops 98 in a widely spacedapart relation adjacent each roof edge 90 and 92.
  • Each loop 98 includes a pair of downwardly diverging legs (not shown), extending through a side wall 14 and 16, fixed to the side wall reinforcing rods 82 and 84.
  • the loops 98 provide engagement means for conventional cranes whereby the modules are movable such as for loading onto or off of transportation means as well as for placement at their final destinations.
  • FIGS. 5, 6 and 7 illustrate three representative groupings of from two to five modules of the present invention.
  • FIG. 5 illustrates an up-and-down arrangement of two modules 100 and 102 which may, for instance, be interiorly finished as a two-bedroom home.
  • Representative end closures are illustrated generally at 104 and 106 although they form no detailed part of the present invention beyond the fact that appropriate closures may be provided at each end thereof.
  • the upper end closure 104 as illustrated, is comprised generally of an arrangement of glass sliding doors 108 which are set back or recessed from the ends of the roof and side walls to form an open balcony 110 spanned by a protective railing 112.
  • the lower end closure 106 illustrates an entrance door 114, a pair of windows 116-116 and a pair of solid lower panels l18ll8.
  • FIG. 6 schematically illustrates a combination of an up-and-down and side-by-side arrangement of four modules of the present invention.
  • the ground level modules 120 and 122 are arranged in a side-by-side relationship and are anchored to prepared footings in a manner to be subsequently described.
  • Side-by-side modules 124 and 126 are anchored atop the ground level modules 120 and 122.
  • FIG. 7 illustrates another combination of modules of the present invention including spaced apart ground level modules 128 and 130 and three side-by-side modules 132, 134 and 136 fixed atop the two ground level modules.
  • the two ground level modules are spaced apart a distance generally equivalent to the width of one module and are provided with respective oppositely extending horizontal ledges 138 and 140 supporting the upper, center module 134.
  • the ledges 138 and 140 are outwardly projecting roof extensions which are appropriately steel reinforced.
  • Both of the module combinations as illustrated in FIGS. 6 and 7 may for instance, be interiorly finished as muIti-bedroom homes or as two family residences.
  • the central open ended covered area 142 of FIG. 7 could provide one or two patio areas for one or two families.
  • the present invention is not limited to the modular arrangements illustrated in FIGS. 5, 6 and 7 nor are they limited to residential usage, being readily adaptable to provide single or multiple office facilities, for example.
  • the modules are substantially the same with the exception that the floor slabs 14 in the upper modules, as seen best in FIG. 6, are positioned closer to the bottom edges 146 and 148 of the side walls 14 and 16 than are the ground level floor slabs.
  • the method of producing the upper modules and the attachment means employed to fix the floor slabs inplace are identical however.
  • the side walls may be extended slightly above the roof level as seen at 150 and 152 on the upper modules.
  • the ground level modules 128 and 130 are formed and reinforced to provide the extending, horizontal ledges 138 and 140 and are in all other respects identical to the basic modules as previously described. In fact, the modules 128 and 130 are identical with one module being reversed with respect to the other.
  • prepared opening forms are accurately positioned in the main forms, prior to casting the concrete structures, to provide desired doorways between sideby-side modules and stairways between the different floor levels.
  • Companionate openings are formed in the top or roof section of the lower level module and in the floor slab of the upper level module to provide for the staircase.
  • any desired openings such as windows, doorways or staircase openings can be readily provided for in the initial forming of the tunnel-shaped member and'the floor slab 18 as schematically indicated by the broken lines 160 and 162 in FIG. 1.
  • FIGS. 8, 9 and 10 are enlarged detailed views illustrating generally the manner in which the upper modular units in FIGS. 5, 6 and 7 are seated on the tops or the roofs of the lower or ground level modules.
  • FIG. 8 illustrates the connection within the curved line 8--8 in FIG. 6 which is representative of the single connections between both side walls 14 and 16 of the upper modules to the roofs of the lower modules in FIGS. 5, 6 and 7.
  • a wooden strip 170 is fixed by any convenient means along the upper surface 172 of the roof 12 of the ground level module.
  • the wooden strip 170 is parallel with the longitudinal edge 174 of the roof and is spaced inwardly therefrom a distance somewhat greater than the thickness of the base portion 176 of the outside wall of the upper module 10.
  • a bed of a suitable grout material 178 is applied between the strip 170 and the longitudinal roof edge 174.
  • each strip 184 and 186 provides a female slot 188 and 190 which respectively receive one of a pair of inwardly projecting, elongated, beaded male projections 192 and 194 formed integral with the trim strip 182.
  • the trim strip 182 is generally channel configurated in cross section and spans the strips 184 in a snap-on, enclosing relation.
  • FIG. 9 is an enlarged detailed view of the inside wall connections between upper and lower pairs of side-byside modules as indicated by the curved line 99 in FIG. 6.
  • the lower pair of building modules -l22 and the upper pair thereof 124-126 are spaced sightly apart as indicated respectively at 200 and 202.
  • a strip of a compressible material 204 is inserted somewhat downwardly into the slot formed at 202 and a pair of wooden strips 206 and 208 are fixed to the respective top surfaces of the roofs of the lower modules 120 and 122 in the same relation to the respective opposed inner roof edges 210 and 212 as are the wooden strips 170 to the outside roof edges 174.
  • a grout bed 214 is applied between the lengths of the wood strips 206 and 208 and when the upper modules 124 and 126 are seated in place on the grout bed 214, the grout material is compressed and forms longitudinal, upwardly extending beads 216, 218 and 220 respectively between the wood strips 206, 208 and the base portions 222, 224 and into the slot formed at 200.
  • FIG. 10 The connections between the spaced apart ground level modules 128 and 130 and the three side-by-side upper level modules 132, 134 and 136 is detailed in FIG. 10 as indicated by the curved line 1010 of FIG. 7.
  • Each connection is substantially the same as described relative to the upper and lower pairs of side-byside modules and prime designations are applied to all of the reference numerals of FIG. 9 with the exception that one wood strip 230 is fixed along the outer vertical edge 232 of each roof ledge 138 and 140.
  • An upwardly extending portion 234 thereof cooperates with the strip 206' to contain the grout bed 214'.
  • FIG. 11 is an enlarged, detailed sectional view indicated by the curved line 11-l1 of FIG. 6 which is representative of the spaced-apart anchor means, employed to anchor all of the side walls of the ground level modules to their respective footings or foundations F.
  • the anchor means is comprised of a plurality of spaced-apart nuts formed as coils of a relatively heavy wire 54, formed in the base portions of the side walls in the same manner as the nut means 28 in the floor slabs.
  • Each coil formed nut 54 is downwardly directed and is threadedly engaged by a headless bolt 240 which projects downwardly beyond the base portion for passage into a vertically formed hole 242 in the footing or foundation F.
  • a suitable grout material 244 is placed in the hole 242 along with a grout bed 246, along the length of the footing or foundation, prior to lowering of the ground level modules into place thereon.
  • the anchor means illustrated in FIG. 11 and above described, is also preferably employed in combination with the grouted connection means illustrated in FIGS. 8, 9 and 10 to anchor the base portions of the side walls of the upper modules to the tops or roofs of the ground level modules.
  • each module comprising,
  • B a steel reinforced, poured concrete floor slab positioned between the side walls, upwardly of the lower ends thereof;
  • said module including interconnecting means between the base portions of said side walls and a prepared footing or foundation at the building site;
  • said interconnecting means comprising a plurality of spaced-apart nuts cast into said base portions and bolt means, threadably received in said nuts and projecting generally, vertically, downwardly below said base portion to be received in grout filled holes provided in the footing or foundation, a grout bed being provided along the top surface thereof to seat said base portions.
  • a building module as defined in claim 2 wherein said fastening means comprises a plurality of bolts extending through appropriate hole means in the side walls into respective threaded engagement with said nuts.
  • each of said nuts is formed as a coil of relatively heavy gauge steel wire and each of said bolts includes a head, and a shank portion having threads configurated for mating reception by one of said coils.
  • said hole means comprises a through hole for each of said bolts, each of said through holes having an enlarged diameter outer portion to provide a shoulder to seat an enlarged washer carried by each of said bolts.
  • a building module as defined in claim 7 including opposed longitudinal grooves formed respectively in each longitudinal edge of said floor slab and its adjacent side walls, said longitudinal grooves and clearance space being filled with an appropriate grout material.
  • each of said nuts is formed as a coil of a relatively heavy gauge steel wire and each of said bolts is headless and provides threads configurated for mating reception by said coils.
  • a building module as defined in claim 10 wherein appropriate holes are formed and filled with grout in the roof of a ground level module to receive said projecting bolt means in the base portion of an upper level module to interconnect the modules in a stacked relation.
  • Building modules as defined in claim 1 having side edges and including interconnecting means between vertically stacked building modules comprising, strip means of a material such as wood fixed to the top of the roof of the ground level module inwardly of the side edges thereof where the base portions of the walls of the upper level module are to be seated, said strip means being spaced inwardly a distance somewhat greater than the thickness of the side walls; an appropriate grout material is applied between said strip means and said side edges to seat the base portions of the walls of the upper level moudle, said upper and lower walls being in a general coplanar relation and said grout material thereby being compressed, forming upwardly extending longitudinal beads inbetween the inner edges of the base portions and said strip means.
  • strip means are fixed to the tops of the roofs, inwardly. of the side edges thereof, of the adjacent edges of a pair of closely spaced-apart ground level modules, a strip of a resilient material such as plastic is inserted downwardly between the modules to seal the space, an appropriate grout material is applied between said strips to seat the base portions of the walls of a pair of similarly spaced-apart upper level modules whereby said grout material is compressed, forming upwardly extending longitudinal beads inbetween the opposed outer edges of the base portions of the upper level modules and inbetween the inner edges of said base portions and the respective strips.

Abstract

Prefabricated building modules of a generally elongated tunnel configuration, each module generally being comprised of a unitarily formed, steel reinforced, poured concrete roof portion and side walls extending the length of the roof, the opposed ends thereof being open. A steel reinforced concrete floor slab is formed in a position relative to the roof and side walls whereby it is in direct alignment with and at the proper elevation to be moved between the side walls to its permanent position, means being provided to securely fix the floor slab in place. End closures are then put in place and the interior is finished and equipped for the purpose for which it is to be used. One module may be used individually or two or more modules may be arranged in various stacked and/or side-by-side and spaced-apart arrangements.

Description

United States Pat ent 1191 Wainshal Aug. 20, 1974 [5 BUILDING MODULES 172,023 6/1965 U.S.S.R 52/236 [76] Inventor: Harouzi Wainshal, 1210 Alfonso OTHER PUBLICATIONS Coral Gables 33134 Civil Engineering, Dec. [964, page I 17. [22] Filed: June 26, 1972 Primary Examiner-Frank L. Abbott [21] Appl' 5957 Assistant Examiner-Henry E. Raduazo [52] US. Cl 52/79, 52/236, 5522/;22955, [57] ABSTRACT 51 1111. c1 E04b l/348 Prefabricated building "mules Of a generally [58] Field of Search 52/79 236 583 587 125 gated tunnel configuration, each module generally 5 being comprised of a unitarily formed, steel reinforced, poured concrete roof portion and side walls [56] References Cited extending the length of the roof, the opposed ends thereof being open. A steel reinforced concrete floor UNITED ATE PATENTS slab is formed in 'a. position relative to the roof and 2,645,l l4 7/1953 Am1r1k1an 52/259 side walls whereby it i in direct alignment i and at Graham the proper elevation to be moved between the side 346O3O8 41969 5/2/79 wallsto its permanent position, means being provided 3 678 638 7/1973 52/79 to securely fix the floor slab in place. End closures are 317211052 3/1973 B0el................... 2.11.1: 52 79 P in PiaCe and the interior is finished and 3,724,142 1/1973 Worthington 52/79 q pp for the P p for which it is to h used- 3,724,157 4/1973 Miram 52/125 One module may be used individually or two or more FOREIGN PATENTS OR APPLICATIONS modules may be arranged in various stacked and/or 2 006 874 9/1970 6 52,79 side-by-side and spaced-apart arrangements.
, ermany 1.
103,085 12/1963 Norway 52/587 15 Claims, 11 Drawing Figures PATENTED M920 1974 viii 3 BUILDING MODULES STATE OF THE PRIOR ART In recent years, because of the ever increasing cost of conventional building construction, the use of various new prefabrication methods and construction techniques have become increasingly popular. The use of standardized methods and equipment to produce the prefabricated structures and modules on a relatively large scale at a permanent base of operations provides a very substantial savings over the cost of a custom built structure or structures produced at large on-site developments.
For instance, many homes are being prefabricated in sections which are sized for over-the-road transportion on tractor-trailer type of vehicles. Foundations and the various plumbing and electrical outlets are prepared in advance at the buliding site and the various sections of the buildings are lifted from the truck by crane means and properly positioned on the foundations and the various plumbing and electrical connections are made between the structure and'the prepared on-site outlets. Most structures of this type are basically of wood construction and each section thereof is basically different to form various portions of the home.
BACKGROUND OF THE PRESENT INVENTION The present invention pretains to building modules of steel reinforced, poured concrete construction which may, for instance, be used individually as a relatively small apartment sized home or, with no basic modifications, can be stacked and/or placed side-by-side to provide relatively large multi-bedroom single or multifamily residences.
Each module is sized for over-the-road transportation and is provided with book means for engagement by appropriate crane means to permit ready movement thereof such as for loading onto and off of the bed of a tractor-trailer truck. The roof and side walls of each module are unitarily formed of steel reinforced, poured concrete and the floor slab is individually, similarly formed and moved into its permanent position between the walls and securely fixed in place by bolt means passed through the side walls into threaded engagement with nut means cast into the floor slab.
The assembled roof, side walls and floor form an elongated, open ended generally tubular or tunnel configurated structure. The ends are then provided with closures which are preferably some type of glass enclosure such as glass sliding doors or an entry door in combination with various types of fixed and openable windows. Various interior arrangements are provided in the modules. For instance, when a module or two or more modules in combination are to be used as a private residence or multiple residence, various room arrangements are provided in each module to form a floor plan quite similar to a conventionally constructed home.
Generally, each module is sized to accommodate two rooms, one adjacent each end thereof, and various combinations of bathrooms, kitchens, closets and stairways, for two story arrangements, inbetween the two rooms. With the use of glass end closures, side wall windows are generally not necessary, However, any side wall or roof openings that are required for side-by-side or up-and-down installations to accommodate doorways, stairs or the like are provided for by properly positioning forms in the main form before pouring the concrete. Side windows, if desired, may also be accommodated in the same manner.
Anchor means are provided to anchor ground level modules to the footings or foundations and to anchor the various arrangements of multiple, stacked and/or sideby-side modules together.
The modules of the present invention provide a great deal of flexibility and may be used for purposes other than private residences such as for apartment or office buildings.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic perspective view of a module roof and side wall structure in accordance with the present inventon and a floor slab positioned to be moved into place between the side walls thereof;
FIG. 2 is a vertical cross sectional view through a typical modular assembly of this invention;
FIG. 3 is an enlarged detailed view of the area within the curved line 3--3 of FIG. 2;
FIG. 4 is a longitudinal sectional view taken along the line 4-4 of FIG. 3;
FIG. 5 is a front elevational view of a pair of modules in a stacked relation;
FIG. 6 is a schematic illustration of four modules in a side-by-side and a stacked relationship;
FIG. 7 is a view similar to FIG. 6 illustrating two spaced apart ground level modules and three second story modules thereatop with the center module spanning the space between the two ground level modules;
FIG. 8 is an enlarged detail of the area within the curved line 8-8 of FIG. 6;
FIG. 9 is an enlarged detail of the area within the curved line 99 of FIG. 6;
FIG. 10 is an enlarged detail of the area within the curved line l010 of FIG. 7; and
FIG. 11 is an enlarged sectional view of the area within the curved line lll1 of FIG. 6.
DETAILED DESCRIPTION OF THE DRAWINGS With reference to the drawings wherein like reference characters designate like or corresponding parts throughout the various views, and with particular reference to FIG. 1, the numeral 10 genrally designates an elongated, generally tunnel shaped structure comprised of a roof l2 and opposed side walls 14 and 16 in accordance with the present invention. Numeral 18 generally indicates a floor slab, positioned to be moved into its proper position between the side walls 14 and 16.
In practice, the tunnel structure is cast of steel reinforced poured concrete in forms, accurately positioned relative to a pair of rails 20 and 22 which are traversed by a flat-bed truck means 24. The flat-bed truck is provided with wheels 26 which are adapted to ride in the rails 20 and 22. The floor slab 18 is formed and cast of poured concrete on the fiat-bed truck at a location removed from the tunnel structure forming area and when the concrete of both structures has set sufficiently, the forms are removed and the floor slab is moved along the tracks 20, 22 on the flat-bed truck, comprising the bottom form for the slab, into position between the side walls 14 and 16. The tunnel structure form, the rails 20 and 22, the size and height of the flatbed truck are prearranged whereby the base slab 18 is properly positioned between the side walls 14 and 16 to be permanently attached therebetween in the following manner.
With reference to FIGS. 3 and 4, a plurality of nut means 28 are cast in predetermined spaced positions within and along both edge portions 30 of the concrete floor slab 18. Appropriate through apertures 32 are provided in the lower portions of the side walls 14 and 16 in alignment with the respective nut means 28 cast within the floor slab 18. After the floor slab 18 is moved to its proper position between the lower end portions of the side walls 14 and 16, bolt means 34 are passed through the apertures 32 into threaded engagement with the respective nut means 28 to fix the floor slab 18 in its permanent position relative to the side walls 14 and 16 of the tunnel shaped structure 10.
As illustrated in FIGS. 3 and 4 each side edge portion of the floor slab 18 is provided with a plurality of longitudinally extending steel reinforcing rods. In a preferred form, four relatively heavy rods 36, 38, 40 and 42 are positioned within each edge portion in a vertically and horizontally spaced relation to form a generally rectangular cross sectional relationship and the four rods 36, 38, 40 and 42 are wrapped along their lengths by a relatively light weight steel wire 44. The assembly of rods 36, 38, 40 and 42 and the wire wrapping 44 are supported along the respective distal end portions 48 of a plurality of spaced-apart transverse slab reinforcing rods 50 and are preferably fixed to the lower rods 40 and 42 by wires or spot-welding. Generally, the transverse rods 50 cooperate with a plurality of spaced-apart, longitudinally extending reinforcing rods 52, FIG. 2, to form a generally conventional, waffie form of steel rod reinforcement for the main body portion of the concrete slab 18.
Each nut means 28 is formed as a coil of a relatively heavy gauge steel wire 54 and includes an inwardly extending loop 56 having a pair of leg portions 58 and 60 fixed in a horizontal relation as by welding along the diametrically opposed, outer sides of the coil 54. The inner or loop end 62 is supported by the outermost longitudinal reinforcing rod 52.
As best illustrated in FIGS. 3 and 4, the concrete slab 18 is formed slightly narrower than the inner width between the side walls 14 and 16 to provide a clearance 63 therebetween on each side. Opposed longitudinal grooves 64 and 66 are formed respectively in each longitudinal edge of the slab l8 and its adjacent side walls 14 and 16 in general alignment with the nut means 28 and the through apertures 32.
As illustrated, each through aperture 32 includes an enlarged outer portion 68 forming a shoulder 70 to seat an enlarged washer 72 fitted about the bolt means 34. Each bolt means 34 is comprised of a headed bolt and a shank portion having threads 74 configurated for mating reception by the steel coil bolt means 32.
The through apertures 32 are filled with an appropriate grout material 76 prior to threading the botls 34 into the nuts 28 and the enlarged outer portions 68 thereof are filled with grout 78, after installation of the bolts 34, to cover the bolt heads. As best illustrated in FIG. 3, the spaces 62 between the slab edges and the inner surfaces of the side walls 14 and 16 as well as the opposed longitudinal grooves 64 and 66 are likewise filled with an appropriate grout material as illustrated at 80. The grouted grooves 64 and 66 form key means to support the slab 18, relative to the side walls 14 and 16, along the lengths of both side edges thereof.
Both side walls 14 and 16 are reinforced by a plurality of vertically and horizontally extending steel rods 82 and 84, generally forming a waffle type network of reinforcing rods. As illustrated in FIG. 2, a pair of relatively heavy, longitudinally extending reinforcing rods 86 are preferably provided along each side wall in spanning relation to the bolt means 34. A similar heavy rod 88 may be provided along the lower ends of the vertical rods 82.
The inner longitudinal corners between the roof edges 90 and 92 and the respective side walls are rounded or coved as illustrated at 94 and 96 and additional steel reinforcing, as generally indicated at 97 in FIG. 2, is provided to add additional strength thereto.
Referring to FIG. 1, loop means 98 extend upwardly and outwardly from the roof. The loop means generally comprise a pair of steel loops 98 in a widely spacedapart relation adjacent each roof edge 90 and 92. Each loop 98 includes a pair of downwardly diverging legs (not shown), extending through a side wall 14 and 16, fixed to the side wall reinforcing rods 82 and 84. The loops 98 provide engagement means for conventional cranes whereby the modules are movable such as for loading onto or off of transportation means as well as for placement at their final destinations.
FIGS. 5, 6 and 7 illustrate three representative groupings of from two to five modules of the present invention. FIG. 5 illustrates an up-and-down arrangement of two modules 100 and 102 which may, for instance, be interiorly finished as a two-bedroom home. Representative end closures are illustrated generally at 104 and 106 although they form no detailed part of the present invention beyond the fact that appropriate closures may be provided at each end thereof. The upper end closure 104, as illustrated, is comprised generally of an arrangement of glass sliding doors 108 which are set back or recessed from the ends of the roof and side walls to form an open balcony 110 spanned by a protective railing 112.
The lower end closure 106 illustrates an entrance door 114, a pair of windows 116-116 and a pair of solid lower panels l18ll8.
FIG. 6 schematically illustrates a combination of an up-and-down and side-by-side arrangement of four modules of the present invention. The ground level modules 120 and 122 are arranged in a side-by-side relationship and are anchored to prepared footings in a manner to be subsequently described. Side-by- side modules 124 and 126 are anchored atop the ground level modules 120 and 122.
FIG. 7 illustrates another combination of modules of the present invention including spaced apart ground level modules 128 and 130 and three side-by- side modules 132, 134 and 136 fixed atop the two ground level modules. In this arrangement, the two ground level modules are spaced apart a distance generally equivalent to the width of one module and are provided with respective oppositely extending horizontal ledges 138 and 140 supporting the upper, center module 134. The ledges 138 and 140 are outwardly projecting roof extensions which are appropriately steel reinforced.
Both of the module combinations as illustrated in FIGS. 6 and 7 may for instance, be interiorly finished as muIti-bedroom homes or as two family residences.
The central open ended covered area 142 of FIG. 7 could provide one or two patio areas for one or two families.
The present invention is not limited to the modular arrangements illustrated in FIGS. 5, 6 and 7 nor are they limited to residential usage, being readily adaptable to provide single or multiple office facilities, for example.
In a stacked or up-and-down arrangement as illustrated in FIGS. 5 and 6, the modules are substantially the same with the exception that the floor slabs 14 in the upper modules, as seen best in FIG. 6, are positioned closer to the bottom edges 146 and 148 of the side walls 14 and 16 than are the ground level floor slabs. The method of producing the upper modules and the attachment means employed to fix the floor slabs inplace are identical however. In addition, the side walls may be extended slightly above the roof level as seen at 150 and 152 on the upper modules.
The ground level modules 128 and 130 are formed and reinforced to provide the extending, horizontal ledges 138 and 140 and are in all other respects identical to the basic modules as previously described. In fact, the modules 128 and 130 are identical with one module being reversed with respect to the other.
When the modules are to be used for various combinations of stacked and/or side-by-side installations,
prepared opening forms (not shown) are accurately positioned in the main forms, prior to casting the concrete structures, to provide desired doorways between sideby-side modules and stairways between the different floor levels. Companionate openings are formed in the top or roof section of the lower level module and in the floor slab of the upper level module to provide for the staircase. As previously stated any desired openings such as windows, doorways or staircase openings can be readily provided for in the initial forming of the tunnel-shaped member and'the floor slab 18 as schematically indicated by the broken lines 160 and 162 in FIG. 1.
FIGS. 8, 9 and 10 are enlarged detailed views illustrating generally the manner in which the upper modular units in FIGS. 5, 6 and 7 are seated on the tops or the roofs of the lower or ground level modules.
FIG. 8 illustrates the connection within the curved line 8--8 in FIG. 6 which is representative of the single connections between both side walls 14 and 16 of the upper modules to the roofs of the lower modules in FIGS. 5, 6 and 7. A wooden strip 170 is fixed by any convenient means along the upper surface 172 of the roof 12 of the ground level module. The wooden strip 170 is parallel with the longitudinal edge 174 of the roof and is spaced inwardly therefrom a distance somewhat greater than the thickness of the base portion 176 of the outside wall of the upper module 10. A bed of a suitable grout material 178 is applied between the strip 170 and the longitudinal roof edge 174. When the upper module is seated in place the foot portion 176 thereof seats in the grout bed 178, compressing same and forming a longitudinal, upwardly extending bead 180 between the wood strip 170 and the base 176. The excess grout material may be troweled off of the outside of the grout bed 178 and a trim strip 182 is applied to the outer wall to cover the joint between the upper and lower modules. A pair of strips 184 and 186 are fixed by any convenient means along the outside of the upper and lower module walls in adjacent, opposed relation to the grout joint 178. Each strip 184 and 186 provides a female slot 188 and 190 which respectively receive one of a pair of inwardly projecting, elongated, beaded male projections 192 and 194 formed integral with the trim strip 182. The trim strip 182 is generally channel configurated in cross section and spans the strips 184 in a snap-on, enclosing relation.
FIG. 9 is an enlarged detailed view of the inside wall connections between upper and lower pairs of side-byside modules as indicated by the curved line 99 in FIG. 6. The lower pair of building modules -l22 and the upper pair thereof 124-126 are spaced sightly apart as indicated respectively at 200 and 202. A strip of a compressible material 204 is inserted somewhat downwardly into the slot formed at 202 and a pair of wooden strips 206 and 208 are fixed to the respective top surfaces of the roofs of the lower modules 120 and 122 in the same relation to the respective opposed inner roof edges 210 and 212 as are the wooden strips 170 to the outside roof edges 174.
A grout bed 214 is applied between the lengths of the wood strips 206 and 208 and when the upper modules 124 and 126 are seated in place on the grout bed 214, the grout material is compressed and forms longitudinal, upwardly extending beads 216, 218 and 220 respectively between the wood strips 206, 208 and the base portions 222, 224 and into the slot formed at 200.
The connections between the spaced apart ground level modules 128 and 130 and the three side-by-side upper level modules 132, 134 and 136 is detailed in FIG. 10 as indicated by the curved line 1010 of FIG. 7. Each connection is substantially the same as described relative to the upper and lower pairs of side-byside modules and prime designations are applied to all of the reference numerals of FIG. 9 with the exception that one wood strip 230 is fixed along the outer vertical edge 232 of each roof ledge 138 and 140. An upwardly extending portion 234 thereof cooperates with the strip 206' to contain the grout bed 214'.
FIG. 11 is an enlarged, detailed sectional view indicated by the curved line 11-l1 of FIG. 6 which is representative of the spaced-apart anchor means, employed to anchor all of the side walls of the ground level modules to their respective footings or foundations F. The anchor means is comprised of a plurality of spaced-apart nuts formed as coils of a relatively heavy wire 54, formed in the base portions of the side walls in the same manner as the nut means 28 in the floor slabs. Each coil formed nut 54 is downwardly directed and is threadedly engaged by a headless bolt 240 which projects downwardly beyond the base portion for passage into a vertically formed hole 242 in the footing or foundation F. A suitable grout material 244 is placed in the hole 242 along with a grout bed 246, along the length of the footing or foundation, prior to lowering of the ground level modules into place thereon.
The anchor means, illustrated in FIG. 11 and above described, is also preferably employed in combination with the grouted connection means illustrated in FIGS. 8, 9 and 10 to anchor the base portions of the side walls of the upper modules to the tops or roofs of the ground level modules.
What is claimed is:
1. Building modules for use singly or in various stacked and/or side-by-side and spaced-apart arrange ments, each module comprising,
A. an elongated, steel reinforced poured concrete,
generally tunnel configurated structure having,
1. a horizontally disposed roof portion, and
2. opposed side walls extending vertically downwardly from the longitudinal side edges of said roof portion;
B. a steel reinforced, poured concrete floor slab positioned between the side walls, upwardly of the lower ends thereof;
C. connector means cast into said floor slab in a spaced relation along both longitudinal sides thereof;
D. fastening means to engage said connector means to fix said floor slab relative to said side walls;
E. said module including interconnecting means between the base portions of said side walls and a prepared footing or foundation at the building site;
F. said interconnecting means comprising a plurality of spaced-apart nuts cast into said base portions and bolt means, threadably received in said nuts and projecting generally, vertically, downwardly below said base portion to be received in grout filled holes provided in the footing or foundation, a grout bed being provided along the top surface thereof to seat said base portions.
2. A building module as defined in claim 1 wherein said cast in means comprises a plurality of spaced apart nuts.
3. A building module as defined in claim 2 wherein said fastening means comprises a plurality of bolts extending through appropriate hole means in the side walls into respective threaded engagement with said nuts.
4. A building module as defined in claim 3 wherein each of said nuts is formed as a coil of relatively heavy gauge steel wire and each of said bolts includes a head, and a shank portion having threads configurated for mating reception by one of said coils.
5. A building module as defined in claim 4 wherein said hole means comprises a through hole for each of said bolts, each of said through holes having an enlarged diameter outer portion to provide a shoulder to seat an enlarged washer carried by each of said bolts.
6. A building module as defined in claim 5 wherein said through holes are filled around said bolts by an appropriate grout material.
7. A building module as defined in claim 1 wherein said floor slab is slightly narrower than the inner width between said side walls to provide a clearance space therebetween on each side.
8. A building module as defined in claim 7 including opposed longitudinal grooves formed respectively in each longitudinal edge of said floor slab and its adjacent side walls, said longitudinal grooves and clearance space being filled with an appropriate grout material.
9. A building module as defined in claim 1 wherein the longitudinal corners between said roof and side walls are interiorly coved.
10. A building module as defined in claim 1 wherein each of said nuts is formed as a coil of a relatively heavy gauge steel wire and each of said bolts is headless and provides threads configurated for mating reception by said coils.
11. A building module as defined in claim 10 wherein appropriate holes are formed and filled with grout in the roof of a ground level module to receive said projecting bolt means in the base portion of an upper level module to interconnect the modules in a stacked relation.
12. A steel reinforced concrete building module as defined in claim 1 wherein said connector means is comprised of a plurality of spaced-apart nuts each'of which is formed as a coil of a relatively heavy gauge steel wire and said fastening means comprises a plurality of bolts extending through said side walls, each including a head portion and a shank portion having threads configurated for mating reception within a respective coil.
13. Building modules as defined in claim 1 having side edges and including interconnecting means between vertically stacked building modules comprising, strip means of a material such as wood fixed to the top of the roof of the ground level module inwardly of the side edges thereof where the base portions of the walls of the upper level module are to be seated, said strip means being spaced inwardly a distance somewhat greater than the thickness of the side walls; an appropriate grout material is applied between said strip means and said side edges to seat the base portions of the walls of the upper level moudle, said upper and lower walls being in a general coplanar relation and said grout material thereby being compressed, forming upwardly extending longitudinal beads inbetween the inner edges of the base portions and said strip means.
14. Building modules as defined in claim 13 wherein strip means are fixed to the tops of the roofs, inwardly. of the side edges thereof, of the adjacent edges of a pair of closely spaced-apart ground level modules, a strip of a resilient material such as plastic is inserted downwardly between the modules to seal the space, an appropriate grout material is applied between said strips to seat the base portions of the walls of a pair of similarly spaced-apart upper level modules whereby said grout material is compressed, forming upwardly extending longitudinal beads inbetween the opposed outer edges of the base portions of the upper level modules and inbetween the inner edges of said base portions and the respective strips.
15. Building modules as defined in claim 10 wherein a pair of strips are fixed along the edge portion of a lower level module in a spaced-apart relation, a suitable grout material is applied inbetween said pair to seat the base portions of the adjacent walls of a pair of closely spaced-apart upper level modules whereby said grout material is compressed, forming upwardly extending longitudinal beads inbetween the opposed outer edges of the base portions of the upper level modules and inbetween the inner edges of said upper base portions and the respective strips.

Claims (16)

1. Building modules for use singly or in various stacked and/or side-by-side and spaced-apart arrangements, each module comprising, A. an elongated, steel reinforced poured concrete, generally tunnel configurated structure having, 1. a horizontally disposed roof portion, and 2. opposed side walls extending vertically downwardly from the longitudinal side edges of said roof portion; B. a steel reinforced, poured concrete floor slab positioned between the side walls, upwardly of the lower ends thereof; C. connector means cast into said floor slab in a spaced relation along both longitudinal sides thereof; D. fastening means to engage said connector means to fix said floor slab relative to said side walls; E. said module including interconnecting means between the base portions of said side walls and a prepared footing or foundation at the building site; F. said interconnecting means comprising a plurality of spacedapart nuts cast into said base portions and bolt means, threadably received in said nuts and projecting generally, vertically, downwardly below said base portion to be received in grout filled holes provided in the footing or foundation, a grout bed being provided along the top surface thereof to seat said base portions.
2. opposed side walls extending vertically downwardly from the longitudinal side edges of said roof portion; B. a steel reinforced, poured concrete floor slab positioned between the side walls, upwardly of the lower ends thereof; C. connector means cast into said floor slab in a spaced relation along both longitudinal sides thereof; D. fastening means to engage said connector means to fix said floor slab relative to said side walls; E. said module including interconnecting means between the base portions of said side walls and a prepared footing or foundation at the building site; F. said interconnecting means comprising a plurality of spaced-apart nuts cast into said base portions and bolt means, threadably received in said nuts and projecting generally, vertically, downwardly below said base portion to be received in grout filled holes provided in the footing or foundation, a grout bed being provided along the top surface thereof to seat said base portions.
2. A building module as defined in claim 1 wherein said cast in means comprises a plurality of spaced apart nuts.
3. A building module as defined in claim 2 wherein said fastening means comprises a plurality of bolts extending through appropriate hole means in the side walls into respective threaded engagement with said nuts.
4. A building module as defined in claim 3 wherein each of said nuts is formed as a coil of relatively heavy gauge steel wire and each of said bolts includes a head, and a shank portion having threads configurated for mating reception by one of said coils.
5. A building module as defined in claim 4 wherein said hole means comprises a through hole for each of said bolts, each of said through holes having an enlarged diameter outer portion to provide a shoulder to seat an enlarged washer carried by each of said bolts.
6. A building module as defined in claim 5 wherein said through holes are filled around said bolts by an appropriate grout material.
7. A building module as defined in claim 1 wherein said floor slab is slightly narrower than the innEr width between said side walls to provide a clearance space therebetween on each side.
8. A building module as defined in claim 7 including opposed longitudinal grooves formed respectively in each longitudinal edge of said floor slab and its adjacent side walls, said longitudinal grooves and clearance space being filled with an appropriate grout material.
9. A building module as defined in claim 1 wherein the longitudinal corners between said roof and side walls are interiorly coved.
10. A building module as defined in claim 1 wherein each of said nuts is formed as a coil of a relatively heavy gauge steel wire and each of said bolts is headless and provides threads configurated for mating reception by said coils.
11. A building module as defined in claim 10 wherein appropriate holes are formed and filled with grout in the roof of a ground level module to receive said projecting bolt means in the base portion of an upper level module to interconnect the modules in a stacked relation.
12. A steel reinforced concrete building module as defined in claim 1 wherein said connector means is comprised of a plurality of spaced-apart nuts each of which is formed as a coil of a relatively heavy gauge steel wire and said fastening means comprises a plurality of bolts extending through said side walls, each including a head portion and a shank portion having threads configurated for mating reception within a respective coil.
13. Building modules as defined in claim 1 having side edges and including interconnecting means between vertically stacked building modules comprising, strip means of a material such as wood fixed to the top of the roof of the ground level module inwardly of the side edges thereof where the base portions of the walls of the upper level module are to be seated, said strip means being spaced inwardly a distance somewhat greater than the thickness of the side walls; an appropriate grout material is applied between said strip means and said side edges to seat the base portions of the walls of the upper level moudle, said upper and lower walls being in a general coplanar relation and said grout material thereby being compressed, forming upwardly extending longitudinal beads inbetween the inner edges of the base portions and said strip means.
14. Building modules as defined in claim 13 wherein strip means are fixed to the tops of the roofs, inwardly of the side edges thereof, of the adjacent edges of a pair of closely spaced-apart ground level modules, a strip of a resilient material such as plastic is inserted downwardly between the modules to seal the space, an appropriate grout material is applied between said strips to seat the base portions of the walls of a pair of similarly spaced-apart upper level modules whereby said grout material is compressed, forming upwardly extending longitudinal beads inbetween the opposed outer edges of the base portions of the upper level modules and inbetween the inner edges of said base portions and the respective strips.
15. Building modules as defined in claim 10 wherein a pair of strips are fixed along the edge portion of a lower level module in a spaced-apart relation, a suitable grout material is applied inbetween said pair to seat the base portions of the adjacent walls of a pair of closely spaced-apart upper level modules whereby said grout material is compressed, forming upwardly extending longitudinal beads inbetween the opposed outer edges of the base portions of the upper level modules and inbetween the inner edges of said upper base portions and the respective strips.
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US4604839A (en) * 1984-05-03 1986-08-12 Esposito John M Tomb module
US5072554A (en) * 1990-04-27 1991-12-17 The United States Of America As Represented By The Secretary Of The Air Force Prefabricated modular storage building
US5199233A (en) * 1990-05-23 1993-04-06 Misawa Homes Co. Ltd. Prefabricated concrete basement and process for constructing the same
US6067771A (en) * 1995-01-19 2000-05-30 Blankenship; Ralph N. Method and apparatus for manufacturing modular building
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US4073104A (en) * 1974-04-19 1978-02-14 Bolanz Gerrit M Building construction system
US6457281B1 (en) * 1980-06-24 2002-10-01 Teron International Building Technologies Ltd. Modular building systems
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US5072554A (en) * 1990-04-27 1991-12-17 The United States Of America As Represented By The Secretary Of The Air Force Prefabricated modular storage building
US5199233A (en) * 1990-05-23 1993-04-06 Misawa Homes Co. Ltd. Prefabricated concrete basement and process for constructing the same
US6067771A (en) * 1995-01-19 2000-05-30 Blankenship; Ralph N. Method and apparatus for manufacturing modular building
US6826879B1 (en) 1999-02-19 2004-12-07 Cathartes Investment Modular building construction
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US20120110928A1 (en) * 2009-06-22 2012-05-10 Liberman Barnet L Modular Building System For Constructing Multi-Story Buildings
US8919058B2 (en) * 2009-06-22 2014-12-30 Barnet L. Liberman Modular building system for constructing multi-story buildings
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GB2491144A (en) * 2011-05-25 2012-11-28 Dainius Simkus Precast modular building unit
US20170044754A1 (en) * 2011-10-19 2017-02-16 Eduardo Ricardo Aguila Precast modular living habitat
US20220002991A1 (en) * 2020-05-19 2022-01-06 Pre-Form Systems System and method for modular construction
US11732465B2 (en) * 2020-05-19 2023-08-22 Pre-Form Systems System and method for modular construction

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