Modules for use in preparing prefabricated structures, method for manufacturing modules, and transport frames - Patents.com

Abstract

The present invention provides a reinforced concrete module for use in preparing a prefabricated structure, the module comprising a horizontal slab, four corner posts, perimeter beams extending downwardly from each of the longitudinal and lateral edges of the horizontal slab and between and connected to adjacent posts, and at least two transverse ribs disposed on the underside of the horizontal slab and extending between two opposing perimeter beams. The module is manufactured as a single piece. Also provided is a method of manufacturing the module, and a transport frame configured to support the module on a transport vehicle.

Description

Detailed Description of the Invention

[0001] [Field of the Invention] The present invention relates to the field of prefabricated buildings, in particular modular reinforced concrete construction.

[0002] [background] WO 2018 / 174825 discloses a method for constructing a prefabricated finished space structure (PPVC) module for a building, the method comprising: (i) pouring concrete to form a body of the PPVC module, the body of the PPVC module comprising one or more load-bearing columns and beams and six walls including a roof covering the top of the PPVC module; and (ii) substantially finishing the interior of the PPVC module before the PPVC module is transported to a site where it will be assembled into a building.

[0003] US Pat. No. 3,568,380 discloses a prefabricated building unit consisting of a rectangular prefabricated floor panel structure having prefabricated vertical load-bearing columns for attachment at each corner and in the mid-length region of each side.

[0004] EP 3 498 929 A1 discloses a building module having a cubic housing formed from a stackable monolithic cylinder of concrete material, four cylindrical walls forming a floor, a ceiling and side walls, with doors and windows provided in the end walls.

[0005] Thus, there is a need for a modular system that provides high design flexibility for habitable structures formed from one or more modules, while also being easily customizable and transportable.

[0006] This background information is provided to identify information believed by the applicant to be of possible relevance to the present invention. No prior information is necessarily admitted, or construed, as constituting prior art against the present invention. [Summary of the Invention]

[0007] It is an object of the present invention to provide a module for use in preparing a prefabricated structure and a method for manufacturing the same. According to an aspect of the present invention, a reinforced concrete module for use in preparing a prefabricated structure is provided, the module comprising: a horizontal slab defining two opposing longitudinal edges, two opposing transverse edges, and four corners, four corner posts, one at each corner, two longitudinal perimeter beams, each of the longitudinal perimeter beams extending downwardly from a respective longitudinal edge of the horizontal slab and extending between and connected to adjacent columns, two transverse perimeter beams, each of the transverse perimeter beams extending downwardly from a transverse edge of the horizontal slab and extending between and connected to adjacent columns, at least two transverse ribs disposed on the underside of the horizontal slab and extending between the opposing longitudinal perimeter beams, and a mounting element disposed at the bottom of each of the corner posts and configured to be attached to a supporting surface. The module is configured to rest on a support surface. Adjacent columns and lower edges of the perimeter beams define openings configured to receive wall in-fill assemblies. Each of the horizontal slabs, corner posts, perimeter beams, and transverse ribs are fabricated from steel reinforced concrete, and the module is fabricated as a single piece.

[0008] According to another aspect of the invention, there is provided a method of manufacturing a reinforced concrete module, the method comprising the steps of: defining an array of rebar cages including a horizontal slab cage, four corner post cages, four perimeter beam cages, and at least two transverse rib cages, assembling the array to a rebar framework in a formwork to obtain a desired modular shape, the rebar framework and formwork being in an upside-down configuration, pouring a concrete slurry into the formwork in one pour, and allowing the concrete slurry to harden in the formwork for a time sufficient to form the reinforced concrete module.

[0009] According to another aspect of the invention, there is provided a transport frame configured to support one or more modules of the invention on a transport vehicle, the transport frame comprising first and second pairs of support legs, each of the support legs being vertically oriented and having a telescoping leg insert configured to extend upwardly from each support leg, a first transverse stiffening beam extending between each leg of the first pair of support legs, a second transverse stiffening beam extending between each leg of the second pair of support legs, first and second longitudinal stiffening beams extending between the first and second pairs of support legs, a first horizontal support beam extending between and attached to upper ends of the telescoping leg inserts in the first pair of support legs, and a second horizontal support beam extending between and attached to upper ends of the telescoping leg inserts in the second pair of support legs, each of the first horizontal support beam and the horizontal support beam comprising a telescoping arm insert configured to extend outwardly from each end of each support beam. [Brief description of the drawings]

[0010] [Figure 1] 1 shows a perspective view of a half module according to an embodiment of the present invention; [Diagram 2] 1 shows a plan view of a half module according to an embodiment of the present invention; [Figure 3A] FIG. 2 shows a perspective view of a full module according to one embodiment of the present invention. [Figure 3B] FIG. 2 shows a top view of a full module according to one embodiment of the present invention. [Figure 4A] 13 shows a perspective view of a full module according to another embodiment of the present invention. [Figure 4B] 13 shows a plan view of a full module according to another embodiment of the present invention. [Figure 5A] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5B] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5C]1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5D] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5E] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5F] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 5G] 1A-1D show perspective views of different assembly and stacking configurations of a module according to an embodiment of the present invention. [Figure 6A] FIG. 2 illustrates a partial perspective view of an end of a module having a slab opening, according to one embodiment of the present invention. [Figure 6B] FIG. 6B is a top view of the module of FIG. 6A according to one embodiment of the present invention. [Figure 7] FIG. 2 shows a perspective view of a three-module assembly according to an embodiment of the invention, with a close-up inset view of the upper peripheral joints of adjacent modules. [Figure 8] FIG. 2 shows a partial perspective view of a corner post reinforcement body according to one embodiment of the present invention. [Figure 9A] FIG. 2 shows a partial perspective view of the reinforcing bar skeleton of the central column according to one embodiment of the present invention. [Figure 9B] FIG. 2 shows a partial perspective view of a reinforced concrete skeleton at a joint between a central beam and a perimeter beam according to one embodiment of the present invention. [Figure 10] 1 illustrates a cross-sectional view of a corner post in accordance with one embodiment of the present invention. [Figure 11] 1 illustrates a cross-sectional view of a center post according to one embodiment of the present invention. [Figure 12] 1 shows a cross-sectional view of a T-beam according to one embodiment of the present invention. [Figure 13] 1 illustrates a cross-sectional view of a perimeter beam according to one embodiment of the present invention. [Figure 14] 1 illustrates a cross-sectional view of a central beam according to one embodiment of the present invention. [Figure 15]FIG. 1 illustrates a side view of a corner post connection assembly in accordance with one embodiment of the present invention. [Figure 16] FIG. 1 illustrates a perspective view of a corner post connection assembly in accordance with one embodiment of the present invention. [Figure 17] FIG. 1 illustrates a side view of a center post connection assembly in accordance with one embodiment of the present invention. [Figure 18] FIG. 1 illustrates a perspective view of a center post connection assembly in accordance with one embodiment of the present invention. [Figure 19] 1 illustrates a perspective view of the end of a head bar, according to one embodiment of the present invention. [Figure 20] FIG. 2 illustrates an end view of a corner post, in accordance with one embodiment of the present invention. [Figure 21] FIG. 1 illustrates an end view of a center post according to one embodiment of the present invention. [Figure 22] FIG. 2 shows a perspective view of a reinforced concrete body of a corner post according to one embodiment of the present invention. [Figure 23] FIG. 2 shows a perspective view of the reinforcing bar skeleton of the central column according to one embodiment of the present invention. [Figure 24A] FIG. 13 shows a side view of the rebar skeleton of a long side of a full module according to one embodiment of the present invention. [Figure 24B] FIG. 13 shows a side view of a rebar skeleton on a long side of a full module according to another embodiment of the present invention. [Diagram 25] FIG. 13 illustrates a side view of the rebar skeleton on the side of the module, according to one embodiment of the present invention. [Figure 26] FIG. 2 is a perspective view of a half module according to one embodiment of the present invention, partially cut away to show the rebar skeleton. [Figure 27A] FIG. 2 is a perspective view of a full module according to one embodiment of the present invention, partially cut away to show the rebar framework. [Figure 27B] FIG. 13 is a perspective view of a full module according to another embodiment of the present invention, partially cut away to reveal the rebar skeleton. [Figure 28]FIG. 2 illustrates a perspective view of a cast portion of a concrete footing assembly according to one embodiment of the present invention. [Figure 29] FIG. 1 illustrates a top plan view of a footing assembly according to one embodiment of the present invention. [Diagram 30] FIG. 1 illustrates a side view of a footing assembly according to one embodiment of the present invention. [Diagram 31] 1 shows a plan view of a footing according to an embodiment of the present invention. [Diagram 32] 1 illustrates a perspective view of a carriage frame in a reduced profile, according to one embodiment of the present invention; [Diagram 33] 1 illustrates a perspective view of a carriage frame in an expanded configuration, according to one embodiment of the present invention. [Diagram 34] FIG. 2 illustrates a perspective view of a transportation frame loaded with full modules, according to one embodiment of the present invention. [Diagram 35] FIG. 2 illustrates a perspective view of a carriage frame loaded with two half modules, according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The term "about" as used herein refers to an error of ±10% from the normal value, and such errors, whether or not specifically mentioned, should always be understood as being included in the given values ​​provided herein.

[0012] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0013] The present invention provides a preformed reinforced concrete module suitable for use in the construction of a habitable structure. The module is manufactured using preformed standard Portland cement construction with steel rebar reinforcement and a substructural design of ceiling / roof slab on supports. In a preferred embodiment, the module is manufactured as a single unit.

[0014] In a preferred embodiment, the modules are pre-fabricated in a factory and transported by conventional flatbed tractor-trailer along existing roads / highways to the site where they are assembled into the final structure.

[0015] In accordance with the present invention, modules may be provided as rectangular full modules or square half modules, in either case capable of being positioned, interconnected, and / or vertically stacked in any combination to form a number of different single or multi-storey configurations.

[0016] In a preferred embodiment, the module comprises a horizontal concrete slab defining two opposing longitudinal edges, two opposing lateral edges, four corners, and four corner posts at each corner of the horizontal slab, which form the roof of the single-storey structure while also providing the floor for the upper storey of the stacked construction.

[0017] As shown in FIG. 1, in one embodiment, the modules are square half-modules with horizontal concrete slabs, with the long edges being the same length as the cross edges.

[0018] In another embodiment, the module is a full rectangular module, with the long edges being twice as long as the cross edges, as shown in Figure 3. The rectangular module further comprises two center columns in addition to the four corner columns at each corner of the horizontal slab, the center columns being located at the midpoint of each long edge.

[0019] In accordance with the present invention, two basic module configurations (full module and half module) can be combined to make numerous structural design configurations available. The 2:1 length to width ratio allows multiple modules to be arranged in a variety of adjacent and stacked relationships, thereby allowing flexibility in architectural design.

[0020] Thus, in a preferred embodiment, multiple preformed modules can be assembled together to form a larger structure comprising multiple stacked units. Figures 5A-5G show exemplary configurations that can be achieved using combinations of half and full modules of the present invention, including parallel, vertical, stacked arrangements, and any combination thereof. Although stacked arrangements of up to three units in height are illustrated in the figures, the modules of the present invention have demonstrated load strength values ​​suitable for use in the construction of structures of up to seven stacked units.

[0021] In one embodiment, the modules (both half and full) are designed to be transported to a site for assembly into the final structure without adversely affecting structural integrity and functionality. In a preferred embodiment, the length, width, and height dimensions of the modules correspond to the dimensions of a standard highway-class tractor-trailer and allow for passage under standard bridges for smooth transportation on the highway.

[0022] In a preferred embodiment, the half modules have a length equal to their width. In one embodiment, the length and width of the half modules are from about 2.5 m to about 7.0 m. In one embodiment, the half modules have a length of about 4.5 m and a width of about 4.5 m.

[0023] In a preferred embodiment, a full module has a length that is twice its width. In one embodiment, the length of a full module is from about 5.0 m to about 14 m, and the width is from about 2.5 m to about 7 m. In one embodiment, a full module has a length of about 9.0 m and a width of about 4.5 m.

[0024] In one embodiment, the height of the full and half modules is from about 3.15m to about 3.45m.

[0025] In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to have a weight of less than about 1 MT per square meter of living space. In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to have a weight of about 0.6 MT to about 0.85 MT per square meter of living space. In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to have a weight of about 0.77 MT per square meter of living space.

[0026] In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to weigh less than about 3 MT per cubic meter of usable living space. In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to weigh from about 0.18 MT to about 2.6 MT per cubic meter of usable living space. In one embodiment, the modules of the present invention provide a reinforced concrete structure designed to weigh about 0.22 MT per cubic meter of usable living space.

[0027] In accordance with the present invention, to provide even greater structural strength and torsional stability, the module further comprises perimeter beams extending downwardly from each edge of the horizontal slab and extending between and joined to adjacent columns.

[0028] For half modules, the perimeter beams are provided as two longitudinal perimeter beams extending downwards from each longitudinal edge between adjacent columns and joined to those columns, and as two transverse perimeter beams extending downwards from each transverse edge between adjacent columns and joined to those columns.

[0029] For a full module, the perimeter beams are provided as a longitudinal perimeter beam extending downward from each longitudinal edge and between and joined to adjacent corner and center posts, and two transverse perimeter beams extending downward from each transverse edge and between and joined to adjacent corner posts.

[0030] In accordance with the invention, the module further comprises at least two transverse ribs (or "T-beams") disposed on the underside of the horizontal slab and extending between and joined to opposing longitudinal perimeter beams.

[0031] The combination of the transverse ribs on the underside of the horizontal slab and the "skirt" formed by the perimeter beams around the perimeter edge of the horizontal slab provides bending resistance combined with strength and stiffness. Thus, the presence of the T-beams and perimeter beams provides a reinforced concrete module that is highly resistant to torsional forces without requiring the amount of reinforced concrete typically used to produce a strong, uniform slab of similar strength as known in the art.

[0032] FIG. 1 shows a perspective view of one embodiment of a half module 10, illustrating a horizontal slab 15 and the relative relationship of the four corner posts 12, lifting anchors 75 located at each corner of the horizontal slab, and connection assemblies 40 located at the bottom of each corner post.

[0033] FIG. 2 shows a plan view of a half module 10 according to one embodiment, illustrating the relative relationships of the four corner posts 12, the perimeter beam 17, and the two transverse ribs 29.

[0034] FIG. 3A shows a perspective view of a full module 20 according to one embodiment, illustrating the horizontal slab 25 and the relative relationships between the four corner posts 22, the center post 23, the lifting anchors 75 located at each corner of the horizontal slab, the connection assemblies 40 located at the bottom of each corner post, and the central connection assemblies 45 located at the bottom of each center post.

[0035] FIG. 3B shows a plan view of a full module 20 according to one embodiment, illustrating the relative relationships between the four corner posts 22, the two central posts 23, the peripheral beams 27, 28, the central beam 26, and the four cross ribs 29.

[0036] FIG. 4A shows a perspective view of an alternative embodiment full module 120 without a center post, showing the relative relationship of the four corner posts 122, the lifting anchors 75 located at each corner of the horizontal slab, and the connection assemblies 40 located at the bottom of each corner post.

[0037] FIG. 4B shows a plan view of a full module 120 according to one embodiment, illustrating the horizontal slab 125 and the relative relationships between the four corner posts 122, the perimeter beams 127, 128, the central beam 126, and the four cross ribs 129.

[0038] In one embodiment, perimeter beams are provided to transfer loads from the columns to the perimeter beams, cross beams (ribs) and roof slab. In one embodiment, the perimeter beams are manufactured to be 30 inches (760 mm) deep to achieve the required load capacity for modules with dimensions of 4.5m by 9m. This is a very efficient size that is both transportable and allows for "optimum" living space.

[0039] In one embodiment, each perimeter beam has an opening (or service access) therethrough to allow for the installation of utilities or infrastructure within the structure. In a preferred embodiment, the service access is provided at multiple locations at regular intervals along the length of the beam. The multiple regularly spaced openings ensure that adjacent modules have the same openings regardless of their relative positions, facilitating the movement or sharing of utilities or infrastructure between multiple adjacent modules. In a preferred embodiment, the service access is built in at the time of manufacturing the module, eliminating the need to introduce access openings after the module is manufactured, which could adversely affect the structural integrity of the concrete and reduce the lifespan of the module. By providing the service access openings during manufacturing, post-manufacturing modifications can be avoided.

[0040] In one embodiment of a half module, each of the transverse and longitudinal perimeter beams has two service openings located across its nominal length, i.e., the side of the half structure. Figure 25 shows a rebar body that may be used to form the long sides of a full module according to one embodiment of the invention, which includes service access openings 84 according to one embodiment of the invention.

[0041] In one embodiment of a full module, the long side of the full module has four service accesses and the horizontal perimeter beams have two service accesses. Figure 24A shows a rebar body that may be used to form the long side of a half module according to one embodiment of the invention, which includes service access openings 84. Figure 24B shows the long side of an alternative embodiment of a full module that does not have a central column, also showing service access openings 184.

[0042] The number of facility accesses may vary as dictated by the functional requirements of the final structure, within the technical requirements to maintain the overall structural strength of the module.

[0043] The modules of the present invention may also have openings in the horizontal slab to accommodate structural elements such as stairs between levels, skylights, elevators, mechanical equipment, etc. According to the present invention, the slab openings are provided in the spaces between the beams of the module. In one embodiment, the openings are provided between the perimeter beam and its adjacent transverse rib (T-rib), as shown for example in Figures 6A and 6B. In one embodiment, the openings are provided between the central beam and its adjacent transverse rib. In one embodiment, the openings are provided between adjacent transverse ribs. Figures 6A and 6B show an end of a module according to one embodiment, which has an opening 34 to accommodate a staircase 35.

[0044] FIG. 7 shows an exemplary assembly of three modules, including the module of FIG. 6A. In the embodiment shown in FIGS. 6A and 7, the modules are provided with a vertical recess 38 extending along a vertical plane surrounding the upper outer edge of each module. This recess is provided to ensure the formation of a gap or void 37 between the upper outer edges of the abutting modules. In one embodiment, the top surface of the module is also provided with a horizontal recess 39 extending along a horizontal plane surrounding the upper outer edge of each module. The void 37, shown enlarged in the inset of FIG. 7, together with the horizontal recess 39, form an annular space that allows the application of a sealant to the joints between adjacent modules to provide an external seal against external connection elements or a seal between floors of the stacked configuration. In one embodiment, the sealant is a liquid sealant applied to fill the joints, a foamed material packed into the joints, or a combination of both.

[0045] The modules of the present invention provide a structure with a high ratio of open living space to the volume occupied by the structural columns without sacrificing the strength of the overall structure. The modules of the present invention can also be combined in a variety of different configurations formed from any combination of half and full modules, with or without slab openings, and a wide variety of customizable add-on features.

[0046] Reducing the volume of the structural components of the module (i.e., slabs, columns, and beams) relative to the available living space also reduces the amount of cementitious materials required, resulting in a significant reduction in the energy demand and life cycle carbon footprint of manufacturing and transporting the modules.

[0047] Each of the horizontal slabs, corner and center columns, perimeter beams, center beam, and transverse ribs are formed from reinforced concrete. Exemplary cross-sectional views of these components are provided in Figures 10 to 14, including the corner columns (Figure 10), center columns (Figure 11), transverse ribs (Figure 12), perimeter beams (Figure 13), and center beams (Figure 14). As shown in Figures 8 and 9, each of the corner and center columns is provided with a drive-in connection element 60 at the bottom of the column, which is used to connect to each of the connection assemblies 40, 45 for connection to the supporting surface.

[0048] 26, 27A, and 27B show perspective views of a half module (FIG. 26) and a full module (FIGS. 27A and 27B) embodiment, partially cut away to show the underlying rebar structure.

[0049] The rebar framework for the slabs, perimeter beams, center beams and cross ribs are fabricated using standard rebar assembly methods, while the columns are provided with head bar construction to provide the necessary structural requirements such as strength, but with minimal use of concrete, i.e., minimal column cross section, to meet these structural requirements.

[0050] The head bars 70 are formed by welding square plate washers 71 to the ends of the rebars 72 placed at the top of each column, as shown in FIG. 19. As shown in FIG. 20 and FIG. 21, a number of head bars 70 are used to form a rebar frame around each column, providing the necessary vertical strength at each column. By eliminating the need for the rebars to be bent into an "L" shape at the top, which is typically required in prior art reinforced concrete construction to provide the necessary vertical strength, the bent rebars can be prevented from penetrating into the central space of the column. Thus, as shown in FIG. 8 and FIG. 9A, the head bars also provide a space in the center of each column to accommodate the placement of the driving attachment elements 60.

[0051] 8 and 9A, each column is also provided with a drive-in connection element 60 at its top. A lifting anchor 75 (not shown) can be removably attached to each drive-in attachment element 60 at the top of each corner and, if present, at the top of the central column. The lifting anchors are provided to facilitate lifting of the modules by a crane or the like for loading and unloading onto and from a transporter, as well as for placement on the site of the habitable structure.

[0052] FIG. 9B shows a drive-in connection element 60 on a full modular embodiment that does not include a central post.

[0053] The drive-in mounting elements 60 may be used to attach the connection assemblies to the modules. In one embodiment, the connection assemblies include an upper bracket attached to the upper base plate, a lower bracket attached to the lower base plate, and a pin connecting the upper and lower brackets. The drive-in mounting elements arranged at the bottom of each column are attached to the connection assembly through the upper base plate of the connection assembly by means of a bolt connection, while the other base plate (i.e., the lower base plate) of the connection assembly is bolted to the corresponding surface to which the module is to be mounted. Thus, the connection assemblies arranged at the bottom of the columns of the modules may be used to physically connect the modules to the upper surface of the lower module if the modules are installed in a stacked configuration, or to physically connect the modules to the supporting surface if the modules are installed as a single storey or substorey. Figures 15 and 16 show a connection assembly suitable for use in a corner column, which includes an upper connection base plate 41b, a lower connection base plate 41a, an upper bracket 43b, a lower bracket 43a, a pin 42, and a bolt hole 44. 17 and 18 show a connection assembly suitable for use with a center column, which includes an upper connecting plate 46b, a lower connecting plate 46a, an upper bracket 48b, a lower bracket 48a, a pin 42, and a bolt hole 44. The center column connection assembly is longer than the corner column connection assemblies and includes two bolt holes for attachment to two corresponding bolts on the support surface, as described below.

[0054] The pin connections of the connection assemblies shown in Figures 15-18 are particularly suited for use with the modular system of the present invention. The connection assemblies are designed to limit the transfer of moments from one module to another, or from a module to the support surface on which it rests, while also allowing flexibility in the orientation of modules when vertically stacked or assembled side-by-side.

[0055] According to one embodiment, the connection assemblies can be secured in any orientation to the bottom of the pole and to the respective support surface by means of bolt connections. This modular connection allows for an adjustable solution for different vertical and horizontal configurations of the attached units. In one embodiment, each connection assembly is rotated 90 degrees with respect to the connection assemblies mounted on the adjacent poles.

[0056] The use of pin connections allows modules to be quickly removed for transportation without requiring disassembly steps that can damage the structural integrity of the individual modules.

[0057] In accordance with the present invention, the connection assemblies attached to the bottom of the columns, in the case of a stacked configuration, can be attached to any suitable supporting surface, for example, a concrete foundation slab or footing, or to the top surface of the lower module.

[0058] In one embodiment, the support surface on which the modules are mounted is provided as a foundation footing assembly, as shown in Figures 28-30. In such an embodiment, connection assemblies located at the bottom of the columns of the modules are used to connect to the support surface 56 of the footing columns 53 of the foundation footing assembly 50 by attaching to footing bolts 55 that extend upwardly from the support surface 56.

[0059] In a preferred embodiment, the footing assembly is provided as a preformed hybrid foundation footing that is manufactured at a manufacturing facility and transported to the site. The footing assembly includes a preformed reinforced concrete footing 52, as shown in FIG. 28. The footing 52 is formed as a square concrete body or concrete frame with a central opening. Rebar extends inward and upward from the footing to form a structure for the footing column. In a preferred embodiment, a form that serves as a mold for pouring the footing column is also provided at the manufacturing facility. The assembly is transported to the installation site where it is placed on the ground to form a support surface for one or more modules. At the site, additional concrete is poured in place within the form to provide a footing column with the desired height.

[0060] Performing the final pouring process on-site makes it easier to ensure that the final height of each foundation footing is the same regardless of variations in the ground surface that will receive the foundation footing assembly, and allows for a level final placement of each module. In one embodiment, the bottom surface of the footing assembly base 52 has a central recess to facilitate level placement on uneven ground.

[0061] The use of a footing assembly comprising a combination of preformed foundations and cast-in-place columns has the advantage of reducing costs, both in time and materials, that are typically incurred when installing floor slabs on-site. The footing assembly can also be more easily transported due to its reduced size and weight.

[0062] In one embodiment, the footing assembly, including the concrete base and the footing column, can be poured as a single piece.

[0063] In one embodiment, the method of manufacturing the modules of the present invention comprises providing a rebar core or cage for each of the horizontal slabs, corner posts, center columns, center beams, perimeter beams, and cross ribs, and assembling the cores in a formwork into the desired modular configuration prior to pouring the concrete. The pouring step is performed with the cores of the modules in an upside-down position with the horizontal slabs at the bottom and the columns facing up. Pouring upside-down ensures a smooth and good quality top surface of the modules. In a preferred embodiment, the modules are poured in one pour.

[0064] In one embodiment, one or more bolt inserts are provided in the formwork to form drive bolt inserts in the cast module. In one embodiment, the drive bolt inserts are provided on one or more of the outwardly facing surfaces of the corner and / or center columns, the top surface of the horizontal slab, and / or the bottom surface of the horizontal slab. In one embodiment, drive bolt inserts are provided on all surfaces of the corner and center columns. In one embodiment, drive bolt inserts are provided on all surfaces of the perimeter and center beams. In one embodiment, drive bolt inserts are provided on all surfaces of the cross ribs. In one embodiment, drive bolt inserts are provided in two rows on each surface.

[0065] The provision of bolt inserts allows for the attachment of decorative, structural, or functional elements to the modules. For example, bolt inserts located on the exterior facing surface of a column may be used to attach decorative elements. As another example, bolt inserts located on the interior surface of a horizontal slab may be used to attach ceiling components or support utilities or other infrastructure components.

[0066] The modules of the present invention are formed with an open space extending between adjacent columns. This open design provides a lightweight module suitable for transportation to a site. The open space also provides an opportunity for design flexibility by incorporating a variety of wall in-fill assemblies with different functional characteristics.

[0067] In one embodiment, adjacent posts and lower edges of the perimeter beams define openings configured to receive a wall in-fill assembly. In one embodiment, the wall in-fill assembly is configured to receive one or more decorative, structural, or functional elements. Bolt inserts disposed on faces of the posts facing the open space between adjacent posts facilitate installation of the wall in-fill assembly.

[0068] For example, in-wall assemblies may be used to incorporate functional elements such as window units, door units, wall panels, and insulation.

[0069] In one embodiment, the wall inset assemblies are prefabricated wall units that are assembled into inter-post openings at a factory or on-site after the base modular structure is manufactured to provide options for access, lighting, and heat / energy storage and control.

[0070] In one embodiment, one or more wall infill assemblies are attached to a pre-formed module at a manufacturing facility and transported with the structure to the site, hi one embodiment, the wall infill assemblies are attached to the module at the site.

[0071] As mentioned above, pouring the modules upside down ensures that the top surface of the module is smooth and of good quality. The integrity of the roof surface is important to ensure resistance to the elements, including water impermeability. In a preferred embodiment, it is desired not to coat or prepare the concrete surface to make it water impermeable.

[0072] In one embodiment, the roof surface of the module can be adapted for storm water retention and management by attaching a frame to form a roof catch basin. In one embodiment, the frame can be attached using drive-in mountings located around the perimeter of the roof slab. In one embodiment, means for controlling runoff / discharge of collected water can be incorporated so that the roof catch basin can function as a water management system, for example for irrigation or grey water use. Controlling the runoff from the roof catch basin can mitigate the harmful environmental impacts of runoff being discharged directly into natural bodies of water.

[0073] The impermeable nature of the roof also allows the roof surface to be used as a garden or growing space.

[0074] As previously mentioned, each module may be provided with removable lifting anchors attached to the drive-in mounting elements on the upper surface of the horizontal slab adjacent each column. The lifting anchors are provided to facilitate lifting of the module by a crane or the like for loading and unloading onto and from a transporter, as well as for placement on the site of the habitable structure. In one embodiment, the removable lifting anchors are threaded into the drive-in mounting elements. In one embodiment, a half module uses four lifting points and a full module uses eight lifting points.

[0075] In one embodiment, the module is lifted by a boltable lifting device at the location of the drive-in mounting element. In one embodiment, the boltable lifting device is a bolted lifting plate.

[0076] The design of the modules and their specific components, and the selection of materials for the modules and their components ensure that the resulting structures are recyclable, transportable / mobile, reusable, durable, long-lasting, have the lowest life cycle costs, and provide a net positive environmental impact over their lifetime.

[0077] The modules of the present invention maintain structural integrity during transportation while meeting performance characteristics or exceeding building codes for snow load, wind load, and earthquakes as mandated in the province of Ontario. Additionally, habitable structures constructed utilizing one or more modules of the present invention also comply with these building codes.

[0078] In one embodiment of the present invention, a transport frame configured to support modules on a transport vehicle is provided.

[0079] In use, the transport frame is fixed to the flat bed of a transport vehicle. The transport vehicle (with the transport frame fixed in place) can then move back under the module. When in position, the transport frame can extend and retract to lift the module into the lift position. The frame is raised and lowered hydraulically.

[0080] Each carrier frame has four support legs, including a rear pair and a front pair, connected by stiffening beams extending therebetween. Each support leg has a telescoping leg insert extending vertically upward from its upper end. A hydraulic cylinder is provided within each support leg to raise and lower the leg insert.

[0081] Each carriage frame also has two horizontal support beams, one attached to the upper end of the leg insert of the rear pair of support legs and the other attached to the upper end of the leg insert of the front pair of support legs.

[0082] The transport frame also has telescoping arm inserts extending horizontally from each end of the horizontal support beams. The leg and arm inserts extend after the transport car is returned into position under the modules to lift the modules off the ground and secure them in place during transport.

[0083] Figures 32 and 33 show an embodiment of a carriage frame 300 in different stages of deployment. Shown are the support legs 310, horizontal support beams 320, longitudinal stiffening beams 340, and transverse stiffening beams 330. Figure 32 shows the carriage frame in a reduced configuration, while Figure 33 shows the carriage frame in an extended configuration with telescoping arms 325 and telescoping leg inserts 315.

[0084] Once the module is lowered into position for site installation, the leg and arm inserts are retracted to allow sufficient clearance to allow the transport vehicle to be pulled out from under the module.

[0085] In one embodiment, each transporter will have two transport frames secured to the loading platform. In one embodiment, both transport frames can be lifted simultaneously or separately to accommodate a full module (as shown in FIG. 34), a half module, or two half modules (as shown in FIG. 35).

[0086] The transport frame is designed to reduce / eliminate the need to load / unload modules onto / from a transport vehicle with a crane.

[0087] Additionally, it is extremely useful for on-site staging. No crane is required to load the modules onto the truck, nor to unload them once they are on-site. If a crane is on-site, the truck can be used to facilitate transporting the modules within the site's reach, eliminating the need for very time-consuming and expensive crane relocation and removal (cranes can cost $8,000 to $10,000 or more per day). This makes installation of the modules cost-effective and time-efficient. Lifting and lowering can be accomplished within minutes, considerably faster and less labor-intensive than traditional staging operations. This approach further eliminates the need for costly, meticulous planning and time-consuming transport to the site on the day of installation, where most delays in the construction process occur.

[0088] In one embodiment, a support frame may also be used to help hold the modules in place to form the first floor of a building.

[0089] It will be apparent that the above-described embodiments of the present invention are examples, which may be varied in many ways. Such present or future modifications should not be regarded as departing from the spirit and scope of the present invention, and all such modifications, as would be apparent to one skilled in the art, are intended to be included within the scope of the following claims.

Claims

1. 1. A module of reinforced concrete for use in preparing a prefabricated structure, the module comprising: a horizontal slab defining two opposing longitudinal edges, two opposing lateral edges, and four corners; four corner posts, one at each corner; two longitudinal perimeter beams, each of which extends downwardly from a respective longitudinal edge of the horizontal slab and between and connected to adjacent corner posts; two horizontal perimeter beams, each of which extends downwardly from the horizontal edge of the horizontal slab and between and connected to adjacent corner posts; At least two transverse ribs disposed on the underside of the horizontal slab and extending between opposing longitudinal perimeter beams; a mounting element disposed at a bottom of each of the corner posts and configured to be attached to a support surface; the module is configured to be placed on the support surface; adjacent corner posts and lower edges of the two longitudinal perimeter beams and the two transverse perimeter beams define an opening configured to receive a wall mount assembly; each of the openings extends between the adjacent corner posts and from the lower edges of each of the two longitudinal perimeter beams and the two transverse perimeter beams to the bottom of each of the corner posts; A module, wherein each of said horizontal slabs, said corner posts, said two longitudinal perimeter beams, said two transverse perimeter beams and said transverse ribs are made of steel reinforced concrete, and said module is manufactured as a single piece.

2. The module of claim 1 , wherein said longitudinal edges are the same length as said transverse edges.

3. The module of claim 1 , wherein said long edges are twice as long as said cross edges.

4. The module of claim 1 , further comprising a lifting anchor disposed on an upper surface of the horizontal slab adjacent each corner post.

5. two central posts, each of which is located at a midpoint between each of the longitudinal edges, the longitudinal edges being twice as long as the transverse edges; The module of claim 1 further comprising a central beam extending between the two central posts.

6. The module of claim 5 further comprising a lifting anchor disposed on an upper surface of the horizontal slab adjacent each corner post and each center post.

7. The module of claim 1 , wherein the transverse ribs have a T-shaped cross-sectional shape.

8. 8. A module according to claim 1, wherein the support surface is an upper surface of a horizontal slab of one or more additional modules.

9. 8. The module of claim 1, wherein the support surface is a bottom slab.

10. the support surface comprising a preformed footing adapted to support the bottom of each corner post; The formed footing is a preformed reinforced concrete foundation formed as a square concrete body; a footing column extending upward from the concrete foundation and having an upper surface; and four bolts extending from the top surface of the footing post.

11. The module of claim 10 , wherein the concrete base and the footing column of the preformed footing are poured as a single piece.

12. The module according to claim 1 , wherein the mounting elements are hammer-in mounting elements.

13. The module of claim 12 , wherein the drive-in mounting elements are configured to be attached to corresponding mounting elements on the support surface via connection assemblies.

14. 14. The module of claim 13, wherein the connection assembly comprises an upper bracket connected to an upper connecting base plate and a lower bracket connected to a lower connecting base plate, the upper bracket and the lower bracket being coupled by a pin connection.

15. 7. The module of claim 5 or 6, further comprising one or more bolt inserts disposed on one or more outwardly facing surfaces of the corner posts and / or the central post, on an upper surface of the horizontal slab, and / or on a lower surface of the horizontal slab, the bolt inserts configured to receive a structural or functional element.

16. 16. The module of any one of claims 1 to 15, wherein the wall-mount assembly is configured to receive one or more decorative, structural, or functional elements, the one or more structural elements or the one or more functional elements being selected from a window unit, a door unit, a wall panel, and insulation.

17. The module of claim 16 , further comprising one or more bolt inserts disposed within an inner periphery of the opening, the bolt inserts configured to receive the wall mount assembly.

18. 18. The module of claim 15 or 17, wherein the bolt insert is a drive bolt insert.

19. 19. The module of any one of claims 1 to 18, further comprising an external element selected from a decorative or insulating panel, a balustrade, a solar panel, a wind turbine, a water retention or water management mechanism.

20. 20. The module of claim 1, wherein the two longitudinal perimeter beams and the two transverse perimeter beams further comprise utility access openings that are sized and shaped to provide utility access and / or to receive utility infrastructure.

21. 21. The module of any one of claims 1 to 20, wherein each corner post comprises a plurality of vertical reinforcing elements, each of said vertical reinforcing elements being a head bar with a square plate washer welded to an upper end of each of said vertical reinforcing elements for connection to a slab.

22. 22. A module according to any preceding claim, further comprising a vertical recess extending around the periphery of the upper outer edge of each module.

23. 23. The module of claim 22, further comprising a horizontal recess extending around the periphery of the top surface surrounding the upper outer edge of each module.

24. 24. A module according to any preceding claim, further comprising sealing means arranged to provide a sealing engagement between adjacent modules upon installation.

25. 25. The module of any one of claims 1 to 24, wherein the module is sized to be transported in a standard size tractor trailer.

26. 1. A method for manufacturing a reinforced concrete module, the method comprising the steps of: defining an array of rebar cages comprising a horizontal slab cage, four corner post cages, four perimeter beam cages, and at least two transverse rib cages; assembling the array to a reinforcing bar framework within a formwork to obtain a desired modular shape, the reinforcing bar framework and the formwork being in an upside-down configuration; Pouring a concrete slurry into the formwork; and allowing the concrete slurry to harden within the form for a period of time sufficient to form the reinforced concrete module.

27. 27. The method of claim 26, wherein the rebar cage assembly further comprises two center column cages and a center beam cage.

28. 28. The method of claim 26 or 27, wherein the form further comprises one or more bolt inserts on an inner surface of the form.

29. 29. The method of any one of claims 26 to 28, wherein the casting step is performed in one shot.

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