Pre-fabricated building modules and method of installation

Abstract

A pre-fabricated building module containing components of a typical multi-story housing project and a corresponding method of installation. Each module is configurable to provide one of a variety of room and dual-room layouts. The module's design allows for road transportation and installation by a tower crane typically found in most multi-story construction projects. Module embodiments are provided for enabling drop-in, stack-in, or slide-in installation in most buildings. Each module is preferably stackable with another module of the same type and configured to provide a predetermined amount of support for loads in the surrounding structure. Each module preferably provides all necessary mechanical and electrical components including their section of risers and ventilation shaft, as well as fixtures, fittings, appliances, cabinets, etc. except for the exterior cladding of perimeter walls which are designed for on-site installation. Each module preferably includes panelized interior cladding for built-in room items enabling sub-assembly prefabrication.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 525,250 filed Nov. 25, 2003.FIELD OF INVENTION [0002] The present invention relates in general to modular building construction systems and, more particularly, to an apparatus and method for pre-fabricated building modules for use in the construction of building structures. BACKGROUND OF INVENTION [0003] The cost of construction of a typical multi-story housing project includes significant material and labor costs. The labor costs are increased by the need for the use of specialized workers of many trades on site. The time spent by these specialized workers and the specialization required is heightened by the need for construction to be done on site. Costs and specialization are enhanced by the need for on-site construction to be done in confined spaces. Typically, due to the confined spaces and location of the work site, on-site construction is not performed usin...

AI Technical Summary

Benefits of technology

[0009] An advantage of the present invention is that is provides building modules for production in an industrial environment using modern fabrication technologies. The use of industrialized production has the benefit of providing large economies of cost of construction and in construction time when compared with on-situ conventional construction involving many trades working in rather confined spaces.

[0010] Another advantage of the present invention is that the building modules lightweight design allows for road transportation and installation by a tower crane of the type usually found in most multi-story construction projects.

[0011] Another advantage of the present invention is that the building modules are finished units. Typically each module contains the necessary mechanical and electrical components including their section of risers and ventilation shaft, as well as sanitary fixtures and fittings, appliances, cabinetwork, interior finishes, etc. One exception to complete pre-fabrication off site is that the perimeter walls outside cladding is to be installed in-situ in order to allow for the completion of the electrical installation of the adjacent rooms.

[0012] Still another advantage of the present invention is that the use of panelized interior cladding, which includes built-in items such as medicine cabinets, paper holders, etc., allows for sub-assembly fabrication and contracting, as well as simplifying maintenance and future renovation.

[0013] Another advantage of the present invention is that the building modules can be designed in many varied designs, combinations, and configurations, e.g., dual-bathroom, dual kitchen, bathroom-kitchen combination to suit most building conditions.

[0014] Another advantage of the present invention is that the building modules are compatible with different types of construction such as wood frame, light gauge steel, hot rolled steel, pour-in-place concrete, pre-stressed concrete, etc.

Problems solved by technology

The cost of construction of a typical multi-story housing project includes significant material and labor costs.

The labor costs are increased by the need for the use of specialized workers of many trades on site.

Typically, due to the confined spaces and location of the work site, on-site construction is not performed using the most current fabrication technologies.

Thus, on-site construction does not present the most advantageous industrial environment.

On-site housing construction has the drawback of not taking full advantage of the benefit of economies of scale experienced by other industries operating in a modern automated factory setting.

As a result, the inefficiencies inherent in on-site construction result in wasted time and effort thereby increasing the cost of construction.

The bathrooms and kitchens are typically the most expensive components of a housing project because these rooms require more construction time due to the confined spaces and features of these rooms.

Public regulations generally limit the dimensions of loads that can be transported via the public roads.

Building modules which are bulky can require specialized cranes or similar equipment for installation.

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