Modular Building Systems

Abstract

To explain a manufactured building system.SOLUTION: A building system can include modular components such as floor panels, roof panels, window walls, separating walls, utility walls, end walls, and / or corbel beams.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to modular building systems. [Background technology]

[0002] Traditional construction is done on a building site, with various trades (carpenters, electricians, plumbers, etc.) measuring, cutting, and installing materials as if they were one-off pieces. Furthermore, each tradesperson's tasks are performed in a linear sequence. This results in a time-consuming process that increases the risk of waste, poor installation, and cost overruns. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2017 / 156006 Summary of the Invention [Problem to be solved by the invention]

[0004] The construction of traditional buildings is becoming increasingly expensive and complex. Code changes, a changing environment, and the introduction of new technologies have made building construction more complex than it was a decade ago. In addition, labor availability has declined significantly. As more and more craftspeople retire, fewer and fewer young workers are choosing construction as a career, and the construction industry is experiencing a significant shortage of skilled, capable men and women to perform the increasing construction work. [Means for solving the problem]

[0005] In some embodiments, a modular building system may be provided that includes floor panels, roof panels, window walls, demising walls, utility walls, and end walls.

[0006] In some implementations, a modular building system can include a floor panel including a first cement board layer, a hydronic foam layer disposed below the first cement board layer, and hydronic piping disposed within the hydronic foam layer. The floor panel can also include a second cement board layer disposed below the hydronic foam layer, one or more joists coupled to an underside of the second cement board layer, and one or more gypsum board layers disposed below the one or more joists, the one or more joists coupled to an upper surface of the one or more gypsum board layers. The floor panel can further include one or more insulation layers disposed in a space defined by the second cement board layer, the one or more joists, and the one or more gypsum board layers.

[0007] In some embodiments, the floor panel may further include a first sheet metal member disposed between the second cement board layer and the tops of the one or more floor joists, and a second sheet metal member disposed between the bottoms of the one or more floor joists and the tops of the one or more gypsum board layers. In some embodiments, the first and second cement board layers may be attached to the first sheet metal member via one or more fasteners.

[0008] In some embodiments, the one or more gypsum board layers can comprise two fiberglass sheathed gypsum board layers. In some embodiments, a roof panel can include a roofing material layer, a protective board layer disposed below the roofing material layer, and a rigid insulation layer disposed below the protective board layer. The roof panel can also include vapor retardation disposed below the rigid insulation layer, a first cement board layer, a hydronic foam layer disposed below the first cement board layer, and hydronic piping disposed within the hydronic foam layer. The roof panel can further include a second cement board layer disposed below the hydronic foam layer, one or more floor joists bonded to an underside of the second cement board layer, one or more gypsum board layers disposed below the one or more floor joists, the one or more gypsum board layers bonded to an upper surface of the one or more gypsum board layers, and one or more insulation layers disposed in a space defined by the second cement board layer, the one or more floor joists, and the one or more gypsum board layers.

[0009] The roof panel may further include a first sheet metal member disposed between the second cement board layer and the tops of the one or more floor joists, and a second sheet metal member disposed between the bottoms of the one or more floor joists and the tops of the one or more gypsum board layers. In some implementations, the first cement board layer and the second cement board layer may be attached to the first sheet metal member via one or more fasteners. In some embodiments, the one or more gypsum board layers may comprise two fiberglass sheathed gypsum board layers.

[0010] Some embodiments can include a demising wall having an insulation section, a first gypsum board layer installed on a first side of the insulation section, and a second gypsum board layer installed on a second side of the insulation section opposite the first side. The demising wall can also include a plurality of first hat channels coupled to the first gypsum board layer, a plurality of second hat channels coupled to the second gypsum board layer, a first finish panel coupled to the plurality of first hat channels via a first trim piece, and a second finish panel coupled to the plurality of second hat channels via a second trim piece.

[0011] In some embodiments, the separation wall may include a first sheet metal member positioned on the inner surface of the first gypsum board layer between the insulation and the first gypsum board layer, and a second sheet metal member positioned on the inner surface of the second gypsum board layer between the insulation and the second gypsum board layer.

[0012] In some embodiments, the first gypsum board layer can comprise fiberglass-lined gypsum board and the second gypsum board layer can comprise fiberglass-lined gypsum board.

[0013] Some embodiments can include a utility wall having an insulation section, an insulation board installed on a first side of the insulation section, a first gypsum board layer installed on the insulation board on the first side of the insulation section, and a second gypsum board layer installed on a second side of the insulation section opposite the first side. The utility wall can also include a weather-resistant barrier installed on the first gypsum board layer and a vapor retarder layer installed on the second gypsum board layer.

[0014] In some implementations, the utility wall can include one or more furring members coupled to the exterior of the utility wall above the weather-resistant barrier and one or more exterior finish panels coupled to the one or more furring members. In some implementations, the utility wall can include one or more hat channel members coupled to the second gypsum board layer, one or more trim pieces corresponding to the one or more hat channel members, and one or more interior finish panels coupled to the utility wall via the trim pieces. In some implementations, the insulation can include multiple insulation layers.

[0015] In some implementations, an end wall can include an insulation section, a thermal insulation layer disposed on a first side of the insulation section, a first gypsum board layer disposed on a side of the insulation layer opposite the insulation section, and a weather-resistant barrier disposed on a side of the first gypsum board layer opposite the insulation section. The end wall can also include a second gypsum board layer disposed on a second side of the insulation layer opposite the first side, and a vapor retarder layer disposed on an inner surface of the second gypsum board layer between the second gypsum board layer and the insulation section.

[0016] In some embodiments, the end wall may also include a first metal sheet layer disposed on the inner surface of the insulation layer between the insulation layer and the insulation section, and a second metal sheet layer disposed on the inner surface of the second gypsum board layer between the second gypsum board layer and the insulation section.

[0017] In some implementations, the end wall may also include one or more hat channel members coupled to the second gypsum board layer, one or more interior finish panels coupled to the hat channel members via corresponding trim pieces, and insulation installed in a space defined by the second gypsum board layer, the one or more hat channel members, and the interior finish panels.

[0018] Some embodiments may include a corbel beam having a hollow structural beam and a wide flange beam disposed within the hollow structural beam. The hollow structural beam may be filled with grout to surround the wide flange beam disposed within the hollow structural beam.

[0019] In some embodiments, the corbel beam can comprise a plate located within the hollow structural beam and adjacent to the flange of the wide flange beam within the hollow structural beam. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a cross-sectional view of an exemplary floor panel according to some implementations. [Figure 2] 1 is a cross-sectional view of an exemplary roof panel according to some embodiments. [Figure 3] 3 is a cross-sectional view of an exemplary separation wall according to some embodiments. [Figure 4] 1 is a cross-sectional view of an exemplary separation wall in a doorway, according to some embodiments. [Figure 5] 1 is a cross-sectional view of an exemplary end wall according to some embodiments. [Figure 6] 1 is a cross-sectional view of an exemplary utility wall, according to some embodiments. [Figure 7] 1 is a cross-sectional view of an exemplary window wall according to some embodiments. [Figure 8] 1 is a cross-sectional view of an exemplary corbel beam at a separation wall / utility wall interface, according to some implementations. [Figure 9] 10 is a cross-sectional view of an exemplary corbel beam at a separation wall / window wall interface, according to some embodiments. [Figure 10] 1 is a cross-sectional view of an exemplary corbel beam at an end wall / utility wall interface, according to some embodiments. [Figure 11] 1 is a cross-sectional view of an exemplary corbel beam at an end wall / window wall interface, according to some embodiments. [Figure 12]3 is a cross-sectional view of an exemplary separation wall in a utility wall, according to some embodiments. [Figure 13] 3 is a cross-sectional view of an exemplary separation wall in a window wall, according to some embodiments. [Figure 14] 1 is a cross-sectional view of an exemplary end wall of a utility wall, according to some embodiments. [Figure 15] 3 is a cross-sectional view of an exemplary end wall of a window wall, according to some embodiments. [Figure 16] 1 is a cross-sectional view of an exemplary window wall in a floor panel, according to some embodiments. [Figure 17] 1 is a cross-sectional view of an exemplary end wall of a floor panel, according to some embodiments. [Figure 18] 1 is a cross-sectional view of an exemplary utility wall in a floor panel, according to some embodiments. [Figure 19] 1 is a cross-sectional view of an exemplary corbel beam at the connection of a floor panel and a separation wall, according to some embodiments. [Figure 20] 1 is a cross-sectional view of an exemplary floor panel, according to some embodiments. [Figure 21] 1 is a cross-sectional view of an exemplary floor panel, according to some embodiments. [Figure 22] 1 is a cross-sectional view of an exemplary interior hallway, according to some embodiments. [Figure 23A] 1 illustrates an exemplary utility wall connection, according to some embodiments. [Figure 23B] 1 illustrates an exemplary utility wall connection, according to some embodiments. [Figure 24] 10A-10C illustrate exemplary corbels in separation walls and end walls, according to some embodiments. [Figure 25] 1 illustrates exemplary corbels in separation and utility walls, according to some embodiments. [Figure 26] 10 illustrates exemplary corbels in end walls and window walls, according to some embodiments. [Figure 27]1 illustrates an exemplary entrance door section in a utility wall, according to some embodiments. [Figure 28] 1 illustrates an exemplary entry door, according to some embodiments. [Figure 29] 1 illustrates details of an exemplary entry door jamb, according to some embodiments. [Figure 30] 1 illustrates an exemplary ceiling access door blocking, according to some embodiments. [Figure 31] 1 illustrates an exemplary shower drain and ceiling access door, according to some embodiments. [Figure 32] 1 illustrates an example of a utility wall at a unit entry door, according to some embodiments. [Figure 33] 1 illustrates an example of a bedroom wall door jamb, according to some embodiments. [Figure 34] 1 is a cutaway view of an example bathroom separation wall, according to some embodiments. [Figure 35] 35 is an exploded view of the example kitchen divider wall of FIG. 34, according to some embodiments. [Figure 36] 1 is a cutaway view of an exemplary bathroom end wall, according to some embodiments. [Figure 37] 37 is an exploded view of the exemplary kitchen separation wall of FIG. 36, according to some embodiments. [Figure 38] 1 is an isometric view of an exemplary intermediate floor panel, according to some embodiments. [Figure 39] 39 is an exploded view of the exemplary intermediate floor panel of FIG. 38, according to some embodiments. [Figure 40] 1 is an isometric view of an exemplary bathroom floor panel, according to some embodiments. [Figure 41] 41 is an exploded view of the exemplary bathroom wall floor panel of FIG. 40, according to some embodiments. [Figure 42] 1 is an isometric view of an exemplary window wall floor panel, according to some embodiments. [Figure 43] 43 is an exploded view of the exemplary window wall floor panel of FIG. 42, according to some embodiments. [Figure 44A] 1 is an isometric view of an exemplary door utility wall panel, according to some embodiments. [Figure 44B] FIG. 44B is an exploded view of the exemplary door utility wall panel of FIG. 44A, according to some embodiments. [Figure 45A] 1 is an isometric view of an exemplary kitchen utility wall panel, according to some embodiments. [Figure 45B] 45B is an exploded view of the exemplary kitchen utility wall panel of FIG. 45A, according to some embodiments. [Figure 46A] 1 is an isometric view of an exemplary bathroom utility wall panel, according to some embodiments. [Figure 46B] 46B is an exploded view of the exemplary bathroom utility wall panel of FIG. 46A, according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0021] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like symbols typically identify like components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. Aspects of the present disclosure, as generally described herein and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are contemplated herein.

[0022] The present disclosure is particularly drawn to methods, systems, products, devices, and / or apparatus generally relating to modular building systems and components comprising floor panels, separation walls, end walls, utility walls, and window walls. The present embodiments specifically address the factors discussed above and other considerations that are driving much of the construction process to be completed off-site and occur in a manufacturing environment rather than a construction site environment.

[0023] In some embodiments, a building can have units, dwellings, rooms, etc. with pre-fabricated modular wall, ceiling, and floor panels. In some embodiments, the wall, ceiling, and floor panels may be installed when the building is constructed. The wall, ceiling, and floor panels may provide a portion of the interior and / or exterior of the building. In some embodiments, the wall, ceiling, and floor panels may be coupled to one or more structural framing members of the building. In some embodiments, the wall, ceiling, and floor panels may be attached to structural framing members such as corbels described herein.

[0024] In some embodiments, the material composition of the wall, ceiling, and floor panels and / or corbels may comprise steel. In some embodiments, the material composition may comprise aluminum. In still other embodiments, the wall, ceiling, and floor panels may be made of a variety of construction-friendly materials, ranging from metals and / or metal alloys, wood and wood polymer composites (WPC), wood-based products (lignin), other organic building materials (bamboo), organic polymers (plastics), hybrid materials, earthen materials such as ceramics, or other suitable materials or combinations thereof. In some embodiments, cement, grout, or other pourable or moldable building materials may also be used. In other embodiments, any combination of suitable building materials may be combined, using one building material for some elements of the wall, ceiling, and floor panels and another building material for other elements of the wall, ceiling, and floor panels. The selection of materials may be made from a selection of materials as specified by the International Building Code or based on the knowledge of one skilled in the art when determining the load-bearing requirements of the structure to be constructed. Larger or taller structures may require greater physical strength than smaller or shorter buildings. Tailoring the construction materials to accommodate the size, loads, and environmental stresses of the structure can determine the optimal economical selection of construction materials used for the wall, ceiling, and floor panel components described herein. The availability of various construction materials in different regions of the world can also influence the selection of materials for constructing the systems described herein. The adoption of the International Building Code or similar codes can also influence the selection of materials.

[0025] References herein to "metal" include any construction-grade metal or metal alloy that may be suitable for the fabrication and / or construction of the wall, ceiling, and floor panels, corbels, and / or components thereof described herein. "Wood" includes wood, wood laminate products, pressed wood products, wood polymer composites (WPC), bamboo or bamboo-related products, lignin products, and plant-based products, whether chemically treated, refined, processed, or simply harvested from the plant. "Concrete" or "grout" references herein include any construction-grade hardening composite material comprising cement, water, and granular aggregate. The granular aggregate may comprise sand, gravel, polymers, ash, and / or other minerals.

[0026] Some implementations may allow users to build apartments or hotels using kits of manufactured components (e.g., wall, ceiling, and floor panels), which helps reduce labor costs, speed time to completion, and lower initial costs. Some implementations of modular building systems may include kits of components that are flexible enough to meet many different requirements; for example, the same system can be used to create bedroom walls, living room walls, kitchen walls, and bathroom walls.

[0027] Some embodiments of the manufacturing system described herein can meet, among other things, the above requirements. In some embodiments, the finish base can include a cold-formed steel hat channel that can be attached to any standard wall (e.g., a demising wall). The faces of the hat channel can support simple aluminum extrusions or fiberglass-reinforced pultruded members. Pultruded members are members with a constant cross-section formed by a continuous process for producing a composite material with a constant cross-section, which process includes pultrusion of the material. The extrusions or pultruded members can allow a very wide range of finishes to be attached to and removed from the wall, providing a finishing system that can be repaired with few or no tools. In some implementations, the closure extrusions simply capture the panel edges and snap into the hat channel extrusions. In some implementations, the panels can be of various sizes and thicknesses. In some implementations, the wall system can include shelf brackets. In some embodiments, the same extrusions and pultruded members, with slight modifications, can be used in bathrooms for shower walls, bath walls, etc.

[0028] Some embodiments may have a flexible design that accommodates many different finish material types, such as wood, metal, and quartz stone. Some embodiments may have low-cost standardized components.

[0029] Using certain embodiments, apartment or hotel room walls can be constructed in several different configurations resulting in large-scale, low-cost manufacturing techniques. In some embodiments, shower walls and living room walls can be accommodated with the same standardized components using wet or dry systems.

[0030] Some implementations can include an accessible design that allows electrical equipment, plumbing pipes, and HVAC ductwork to be easily accessible behind the finished panel system. In some implementations, snap-closure angles can include drilled holes (e.g., on-center) to allow for hanging televisions, pictures, etc. Some embodiments can include vertical shelf extrusions that allow for placement of shelves, cabinets, and countertops.

[0031] As designers and builders seek low-cost ways to meet people's built environment needs, one potential solution is an integrated solution. An integrated solution can comprise integrating two (or more) components that are traditionally separate products and installations into a single product solution. Some implementations of the manufactured wall, ceiling, and floor panels described herein comprise an integrated solution that provides a modular building system.

[0032] FIG. 1 is a cross-sectional view of an exemplary floor panel 100 according to some embodiments. The floor panel 100 is configured to form the floor of an upper unit and the ceiling of a lower unit (e.g., the floor of an apartment unit on a given floor and the ceiling of an apartment unit on the floor immediately below the given floor). The floor panel 100 also includes multiple layers. In the description of layers and other components herein, references are made to "field panel installed," "field finish installed," and "factory installed." In some embodiments, "field panel installed" can refer to a panel that is installed on-site by a panel erection crew during the construction process (e.g., at a building site to install the panel on a building). In some implementations, "field finish installed" can refer to a layer or component that is installed on-site by a finish crew during the construction process (e.g., at a building site to a panel installed on a building). In some implementations, "factory installed" can refer to a layer or component that is installed at a factory during the manufacturing process. A factory setting is different from a field or building site setting.

[0033] The layers of the floor panel 100, from top to bottom relative to the building floor, include a finish floor layer 102 (e.g., a 3 / 8 inch (0.95 cm) finish floor installed in a field finish), an acoustic mat layer 104 (e.g., a 3 / 8 inch (0.95 cm) acoustic mat installed in a field finish), a first cement board layer 106 (e.g., a 1 / 2 inch (1.27 cm) cement board layer installed in a factory), a hydronic foam layer 112 (e.g., a 1 inch (2.54 cm) hydronic foam layer installed in a factory), hydronic piping 110 within the hydronic foam layer 112, a second cement board layer 114 (e.g., a 1 / 2 inch (1.27 cm) cement board layer installed in a factory), and a first sheet metal layer 116 (e.g., a 22 ga. galvanized steel sheet metal layer installed in a factory).

[0034] At the factory, the first cement board layer 106 is secured to the first sheet metal layer 116 using first fasteners 108 (e.g., #8 x 2.375 inch (6.03 cm) self-drilling screws on up to 12 inch (30.48 cm) centers). Also at the factory, the second cement board layer 114 is attached to the first sheet metal layer 116 via second fasteners 118 (e.g., #8 x 1-1 / 4 inch (3.18 cm) self-drilling screws).

[0035] Now, proceeding from the bottom up of the floor panel 100, the layers include a factory-installed aluminum light fixture rail 136 extending beneath a ceiling panel layer 134 (e.g., field-installed 1-inch (2.54 cm) acoustical ceiling panel tile), which is held in place by a track 128 (e.g., a factory-installed pultrusion track) attached via track clips 130 (e.g., field-installed aluminum track clips). Above the track clips 130 are one or more gypsum board layers 126 (e.g., two 5 / 8-inch (1.59 cm) Type "X" fiberglass mat gypsum sheathing boards, factory-installed with staggered joints). The track clips 130 are attached to the one or more gypsum board layers 126 via third fasteners 132 (e.g., #6 x 1.1875-inch (3.01625 cm) self-drilling screws).

[0036] A second metal sheet layer 124 (e.g., a factory-installed 22 ga galvanized steel sheet layer) is located above the one or more gypsum board layers 126. A third fastener 132 also extends through the second metal sheet layer 124.

[0037] The first and second sheet metal layers 116, 124 are connected by at least one metal joist 120 (e.g., a 10-inch (25.4 cm) 14 ga metal joist with a 2-1 / 2 inch (6.35 cm) flange installed at the factory). Also disposed in the space between the first and second sheet metal layers 116, 124 are one or more layers of insulation 122 (e.g., two layers of 3-1 / 2 inch (8.89 cm) factory-installed semi-rigid mineral wool batt insulation).

[0038] Thus, for floor panel 100, in some embodiments, the field-installed layers or components include finished floor 102, acoustic mat 104, track clips 130, and ceiling panel 134. The remaining layers and components of floor panel 100 may be installed at a factory to minimize on-site labor.

[0039] 2 is a cross-sectional view of an exemplary roof panel 200 according to some embodiments. The roof panel 200 forms the top horizontal panel of a building, constitutes the ceiling panel of the top floor unit from the inside of the top of the building, and constitutes the roof from the outside of the top of the building. The roof panel 200 comprises multiple layers.

[0040] Starting from the top, from the exterior to the interior, the layers comprising the roof include a roof layer 202 (e.g., a single-ply roof membrane layer), a protective board layer 204 (e.g., a 1 / 2 inch (1.27 cm) protective board layer), and a roof insulation layer 206 (e.g., a rigid insulation layer). In some embodiments, the roof insulation and roof membrane can be installed on-site.

[0041] Continuing inward from the roof, the layers include a vapor retarder layer 208, a cement board layer 210 (e.g., factory-installed ½ inch (1.27 cm) cement board), and a first sheet metal layer 212 (e.g., a 22 ga galvanized steel sheet metal layer). First fasteners 214 are used to attach the vapor retarder layer 208 and the cement board layer 210 to the first sheet metal layer 212.

[0042] Proceeding from the bottom up, the layers of roof panel 200 include a factory-installed aluminum light fixture rail 232 extending beneath a ceiling panel layer 230 (e.g., field-installed 1-inch (2.54 cm) acoustical ceiling panel tile), which is held in place by a track 224 (e.g., a factory-installed pull-out track) attached via track clips 226 (e.g., field-installed aluminum track clips). Above the track clips 226 are one or more gypsum board layers 222 (e.g., two 5 / 8-inch (1.59 cm) Type "X" fiberglass mat gypsum furring boards factory-installed with staggered joints). The track clips 226 are attached to the one or more gypsum board layers 222 via second fasteners 228 (e.g., #6 x 1.1875-inch (3.01625 cm) self-drilling screws).

[0043] A second metal sheet layer 220 (e.g., a factory-installed 22 ga galvanized steel sheet metal layer) is located above the one or more gypsum board layers 222. Second fasteners 228 also extend through the second metal sheet layer 220.

[0044] First sheet metal layer 212 and second sheet metal layer 220 are connected by at least one metal joist 216 (e.g., a 10-inch (25.4 cm) 14 ga metal joist with a 2-1 / 2-inch (6.35 cm) flange installed at the factory). Also disposed in the space between first sheet metal layer 212 and second sheet metal layer 220 are one or more layers of insulation 218 (e.g., two layers of 3-1 / 2-inch (8.89 cm) semi-rigid mineral wool batt insulation installed at the factory).

[0045] 3 is a cross-sectional view of an exemplary demising wall 300 according to some embodiments. A demising wall can comprise a wall that forms a boundary separating one tenant's space from another tenant's space or from a common corridor. A demising wall is also called a separation partition or party wall.

[0046] The separation wall 300 comprises multiple layers and components. From the exterior to the interior of a first side, the multiple layers comprise one or more interior finish panels 302 (e.g., prefabricated, field-installed interior panels approximately 1 foot 4 inches (40.64 cm) tall). The interior finish panels 302 are held in place via trim pieces 304 (e.g., field-installed fiberglass reinforced plastic pultruded trim) having exterior and interior portions. The interior portions of the trim pieces 304 are attached to hat channels 306 (e.g., 2-1 / 2 inch (6.35 cm) deep, 2 inch (5.08 cm) wide, 20-gauge hat channels with 1 inch (2.54 cm) feet on 16 inch (40.64 cm) centers). Hat channel 306 is screwed to gypsum board layer 310 (e.g., 5 / 8 inch (1.59 cm) "X" type fiberglass mat gypsum furring board) and steel sheet 312 (e.g., 22 ga galvanized steel sheet) using fasteners 318. Duct 308 (e.g., 1 / 8 inch (0.32 cm) fiberglass reinforced plastic pull-out duct) can be placed in the space provided by the standoff of hat channel 306 from gypsum board layer 310. In some implementations, duct 308 can be an exhaust for a kitchen, bathroom, dryer, or incoming fresh air.

[0047] A second side of isolation wall 300, opposite the first side, includes a mirror image set of the layers and components described above. In the space between the first and second sides of isolation wall 300 are metal studs 314 (e.g., 25 ga metal studs at 3-5 / 8 inches (9.21 cm) on 24-inch (60.96 cm) centers). Fasteners 318 may extend through the sheet metal layers (e.g., 312) and into metal studs 314. Also disposed in the space between the first and second sides of isolation wall 300 is a layer of insulation 320 (e.g., 3-1 / 2 inches (8.89 cm) of factory-installed semi-rigid mineral wool batt insulation).

[0048] 4 is a cross-sectional view of an exemplary separation wall 400 at a doorway, according to some embodiments. The separation wall 400 shown in FIG. 4 comprises a bedroom wall at a doorway to a bedroom. The cross-sectional view is a horizontal cross-section of the separation wall adjacent to the doorway.

[0049] The separation wall 400 includes an insulation layer 402 (e.g., 3-1 / 2 inch (8.89 cm) semi-rigid mineral wool batt insulation installed at the factory) and one or more metal studs 404 (e.g., 3-5 / 8 inch (9.21 cm) 25 ga metal studs installed at the factory on 24 inch (60.96 cm) centers). The separation wall 400 also includes two gypsum board layers 406, one on each side of the separation wall 400. The gypsum board layers 406 may include 5 / 8 inch (1.59 cm) type "X" fiberglass mat gypsum underlayment board.

[0050] The separation wall 400 also includes interior finish panels 408 disposed on each side of the separation wall 400. The interior finish panels 408 may be installed on-site and held in place by one or more trim pieces 410 (e.g., fiberglass reinforced plastic pultrusion trim).

[0051] The separation wall 440 also includes a hat channel 414 to which the trim piece 410 is attached via first fasteners 412 (e.g., #8 1 / 2 inch (1.27 cm) screws on 48 inches (121.92 cm) center). The hat channel 414 is attached to the gypsum board layer 406 via second fasteners 416 (e.g., #8 1-5 / 8 inch (4.13 cm) screws on 24 inches (60.96 cm) center). The separation wall 400 includes a door opening 418.

[0052] Separation wall 400 includes an end cap member 420 and a trim piece 422 (e.g., angled metal trim) that covers the gap created by hat channel 414 between gypsum board layer 406 and finish panel 408. Door jamb 426 is coupled to the separation wall via fasteners 424. Door 428 is installed in door opening 418.

[0053] 5 is a cross-sectional view of an exemplary end wall 500 according to some embodiments. The end wall 500 can form an exterior wall of the unit (e.g., a wall with one interior wall and the other exterior wall) or an interior wall.

[0054] End wall 500 can comprise multiple layers and components, including (generally from exterior to interior) factory-installed exterior panels 502 (e.g., factory-installed 4 mm aluminum composite panels), furring strips 504 (e.g., factory-installed 1-inch (2.54 cm) extruded aluminum furring strips), a weather-resistant barrier layer 506 (factory-installed), a first gypsum board layer 508 and a second gypsum board layer 508 (e.g., 5 / 8-inch (1.59 cm) "X" type fiberglass mat furring strip), a first insulation layer 510 (e.g., a layer of insulation that is bonded to the studs), and a second insulation layer 510 (e.g., a layer of insulation that is bonded to the studs). (1.27 cm) insulation, factory-installed), first and second sheet metal layers 512 and 512 (e.g., 22 ga galvanized steel sheeting screwed to studs every 12 inches (30.48 cm) on center, factory-installed), metal studs 514 (e.g., 18 ga metal studs at 3-5 / 8 inches (9.21 cm) on 24 inches (60.96 cm) on center), and second insulation layer 518 (e.g., 3-1 / 2 inches (8.89 cm) semi-rigid mineral wool batt insulation, factory-installed).

[0055] Drip flashing 520 (e.g., pre-finished aluminum drip flashing) can be factory-installed at the joints between the exterior finish panels 502. A vapor suppression layer 532 can be factory-installed between the second insulation layer 518 and the second gypsum board layer 508 (e.g., an interior gypsum board layer).

[0056] Continuing from the exterior to the interior, a plurality of hat channels 522 are factory installed in the second gypsum board layer 508 using second fasteners 524. A third insulation 528 is field installed in the end wall 500. A trim 526 is field installed and attached to the hat channels 522 via first fasteners 516.

[0057] 6 is a cross-sectional view of an exemplary utility wall 600 according to some embodiments. The utility wall 600 can form an exterior wall of the unit (e.g., a wall with an interior wall on one side and an exterior wall on the other side) or an interior wall.

[0058] Utility wall 600 includes multiple layers and components that may include (generally from outside to inside) factory-installed exterior panels 602 (e.g., factory-installed 4 mm aluminum composite panels), furring members 604 (e.g., factory-installed 1-inch (2.54 cm) extruded aluminum furring), a weather-resistant barrier layer 606 (factory-installed), first and second gypsum board layers 608 (e.g., 5 / 8-inch (1.59 cm) "X"-type fiberglass mat furring board), and a first insulation layer 610 (e.g., factory-installed 1 / 2-inch (1.27 cm) insulation glued to studs).

[0059] The utility wall 600 may also include a plurality of metal studs 612 (e.g., 10-inch (25.4 cm) 18 ga metal studs), and a second layer of insulation 620, a third layer of insulation 620, and a fourth layer of insulation 620 (e.g., 3-1 / 2-inch (8.89 cm) mineral wool batt insulation, factory installed).

[0060] Drip flashing 616 (e.g., pre-finished aluminum drip flashing) can be factory-installed at the joints between exterior finish panels 602. A vapor suppression layer 630 can be factory-installed between third insulation layer 620 and second gypsum board layer 608 (e.g., interior gypsum board layer).

[0061] Continuing from exterior to interior, a plurality of hat channels 614 are factory installed in the second gypsum board layer 608 using first fasteners 618. Trim is installed in the field finish and attached to the hat channels. The trim is used to hold the interior finish panels in place.

[0062] The utility wall 600 can be equipped with piping 622 (e.g., factory-installed piping such as wastewater, water supply, exhaust, vent, electrical bosses, and feeder cables) held in place by pipe brackets 628 coupled to unistruts 626 inserted into knockouts 624 in the studs 612, all of which are factory-installed.

[0063] 7 is a cross-sectional view of an exemplary window wall 700 according to some embodiments. The window wall 700 includes, among other things, an upper thermal break frame 702 (e.g., a thermal break aluminum frame), a clear or fritted glass 704, and a lower thermal break frame 706 (e.g., a thermal break aluminum frame).

[0064] FIG. 8 is a cross-sectional view of an exemplary corbel beam at a separation wall / utility wall interface according to some implementations. In particular, FIG. 8 shows a horizontal cross-section in the area where a corbel beam 834 is attached to a structural member, for example, a wide-flange steel column 827 that forms part of the structural frame of a building. The corbel beam 834 is attached to a corbel beam connection plate 825, which is connected to a connection plate 826 via one or more bolts 838 and attached to the wide-flange steel column 827. A steel tab erection stop 830 (e.g., a 3-inch (7.62 cm) by 3-inch (7.62 cm) by ¼-inch (0.64 cm) steel tab) is attached to the connection plate 826 to assist in the erection and installation of the corbel beam 834.

[0065] Corbel beam 834 is shown in relation to floor panel 804 and hat channel 802 described above. Also shown are two utility walls 836, one on each side of corbel beam 834. Also shown is corbel beam 828, which connects to wide flange column 827 and extends horizontally along the hallway to the outside of utility wall 836.

[0066] The connection where the corbel beam 834 meets the utility wall 836 includes first insulation 806 (e.g., 4-inch (10.16 cm) compressed semi-rigid mineral wool batt insulation installed at the field finish), angle iron 808 (e.g., 2-inch (5.08 cm) by 3-inch (7.62 cm) by 15-1 / 2-inch (39.37 cm) by 1 / 8-inch (0.32 cm) L-angle iron centered and welded on both sides of the corbel beam 834), and angle gasket 810 (e.g., attached to the angle iron on-site prior to installation of the corbel beam 834 or installed at a factory to protect the corbel beam 834 during transportation). The utility wall 836 also includes a gasket 812 that corresponds to the angle gasket 810. A weather-resistant barrier 814 is applied to each side of the end of the corbel beam 834 and can run over the angle iron 808.

[0067] Second insulation 816 is attached to each side of the ends of the corbel beams 834 (e.g., 1 inch (2.54 cm) semi-rigid mineral wool insulation board factory-bonded to each side of the corbel beams 834). The ends of the utility wall 836 that abut the ends of the corbel beams 834 are attached to third insulation 818 (e.g., 2 inch (5.08 cm) semi-rigid mineral wool insulation board factory-bonded to the ends of the utility wall 836).

[0068] The utility wall 836 includes a closure member 820 that covers the connection between the utility wall 836 and the corbel beam 834. Above the corbel beam 834 is a separation wall (not shown) that is attached to and supported by the corbel beam 834. The closed end of the separation wall is shown in dashed lines at 822.

[0069] Carbon foam beam covers 832 (e.g., the carbon foam beam covers can be CNC machined with bolts and plates and installed at the factory) are attached to the ends of the corrugated beams 834. Sealant 824 (e.g., silicone sealant) is applied in the area where the connecting plates 825 of the corrugated beams 834 pass through the carbon foam beam covers 832. Bolts 840 connect the corrugated beams 834 to the corrugated beam connecting plates.

[0070] Figure 9 is a cross-sectional view of an example of a corbel beam at a separation wall / window wall interface, according to some embodiments. In particular, Figure 9 shows a corbel beam 901 connected to a wide-flange steel column 903 at the connection where a separation wall (not shown, positioned above and supported by the corbel beam 901) meets two window walls 905 and 907. Also connected to the wide-flange steel column 903 are two balcony beams 910 and 911 that extend horizontally outside the window walls 907 and 905, respectively. The edges of the floor panels are also outlined by dashed lines 918.

[0071] A first connecting plate 904 is coupled to a wide flange column 903. A steel tab erection stop 902 (e.g., a 3 inch (7.62 cm) by 3 inch (7.62 cm) by ¼ inch (0.64 cm) steel tab) is coupled to the first plate 904 and provides a stop point for use during building erection and coupling of the corbel beam 901 to the wide flange column 903.

[0072] At the end of the corbel beam 901, a cap plate 924 (e.g., a ½-inch (1.27 cm) steel plate cut parallel to the inside radius of the corbel beam 901 and fabricated to be ⅛-inch (0.32 cm) shorter on all sides, installed at the factory) is joined to the corbel beam 901. The cap plate 924 is used to secure the second plate 912 to the corbel beam 901 via a third plate 916 (e.g., a 5 / 8-inch (1.59 cm) by 8-inch (20.32 cm) by 16-inch (40.64 cm) steel plate) and a plurality of fasteners 928 (e.g., a nut and bolt system). The first plate 904 is connected to the second plate 912 via a plurality (e.g., five) of fasteners 926 (e.g., a bolt and nut system).

[0073] At the factory, beam covers 922 are attached to the ends of the corbel beams 901. The beam covers 922 may comprise CNC-machined carbon foam beam covers with bolts and plates attached to the corbel beams 901. Trim pieces 920 are bonded to the exterior surfaces of the window walls 905 and 907 at the factory. The corbel beams 901 include first insulation 908 (e.g., ½ inch (1.27 cm) insulation notched at a 45-degree angle to accommodate welds, installed at the factory). At each joint where the window walls 905 and 907 meet the corbel beams 901, sealant and backer rods 906 are installed in the field.

[0074] 10 is a cross-sectional view of an exemplary corbel beam at an end wall / utility wall corner interface according to some embodiments. In particular, FIG. 10 shows a corbel beam 1001 connected to a wide flange corridor beam 1022 connected to a structural frame comprising wide flange columns 1009 and wide flange beams 1010.

[0075] Corbel beams 1001 are positioned under and support the end walls (not shown) at the corners where the end walls meet the utility walls 1013. Also shown is the outline of floor panels 1012 located inside the end walls and utility walls 1013.

[0076] The corbel beam 1001 is connected to a wide flange corridor beam 1022 via a first plate 1018 secured to the corridor beam end via fasteners 1030 (similar to the corridor beam end connection shown in FIG. 9 and described above). The first plate 1018 is connected to a second plate 1026 via one or more fasteners 1028 (e.g., a five-bolt and nut combination). The second plate 1026 is connected (e.g., welded) to the wide flange corridor beam 1022. The second plate 1026 includes an erection stop 1024 (e.g., similar to 902 described above) connected to the second plate 1026. A beam cover 1016 (e.g., a carbon foam beam cover) is connected to the end of the corridor beam 1001. A sealant 1020 (e.g., a silicone sealant bead) can be applied at the factory to the seam where the first plate 1018 extends through the beam cover 1016.

[0077] A first insulation 1002 (e.g., field-installed 4-inch (10.16 cm) compressed semi-rigid mineral wool batt insulation) is disposed at the end of the utility wall 1013 in the area between the corbel beam 1001 and the end of the utility wall 1013. An angle iron 1004 (e.g., a 2-3 / 4 inch (6.99 cm) by 2-3 / 4 inch (6.99 cm) by 15-1 / 2 inch (39.37 cm) by 8 inch (20.32 cm) L-angle iron) is coupled (e.g., welded) to the corbel beam 1001. The first insulation 1002 is disposed on a first side of the angle iron 1004. On the other side of the angle iron 1004 is an angle gasket 1006, which can be installed at a factory or on-site prior to installation of the corbel beam to protect the beam. The angle gasket 1006 engages a utility wall gasket 1008 that is coupled to the utility wall 1013 adjacent to a second insulation 1015 that is coupled to an end of the utility wall 1013. The utility wall 1013 includes a closure portion 1014 on the exterior of the utility wall 1013.

[0078] Figure 11 is a cross-sectional view of an exemplary corbel beam at an end wall / window wall interface according to some implementations. In particular, Figure 11 shows a corbel beam 1101 coupled to a sub-cantilever beam 1102 via a first connecting plate 1104, which is coupled to a second connecting plate 1106 via one or more fasteners 1122 (e.g., five bolts and bolt combinations). The second plate 1106 is coupled to the corbel beam 1101 via a third plate 1108 and fasteners 1124 (e.g., similar to those described above in connection with Figure 9).

[0079] The sub-cantilever beam 1102 is connected to a wide flange steel column 1116, which in turn is connected to a wide flange beam 1120. A beam cover 1118 (e.g., a carbon foam beam cover machined with the bolts and plates of the corbel beam 1101) is connected to the corbel beam 1101.

[0080] 11 also shows a window wall 1126 and floor panel contours 1114. End walls (not shown) are supported by corbel beams 1101. The window wall 1126 includes a closure member 1112 (e.g., a factory-installed fiber-reinforced polymer (FRP) pultruded closure). A backer rod and sealant 1110 are placed at the joint between the beam cover 1118 and the window wall 1126.

[0081] FIG. 12 is a cross-sectional view of an exemplary separation wall in a utility wall according to some embodiments. In particular, FIG. 12 shows separation wall 1202 (e.g., similar to 300 described herein) meeting two utility walls 1203 and 1205. Floor panel outlines are shown by dashed lines 1204 and 1208. Utility wall 1203 and utility wall 1205 may be similar to 600 described herein. Separation wall 1202 is supported from below by a lower corrugated beam 1212. Corrugated beam 1212 is connected to wide-flange steel column 1228 via corrugated beam connection 1230 (described in more detail in connection with FIG. 9 herein). Wide-flange steel column 1228 is connected to wide-flange corridor beam 1226.

[0082] The interface between each side of the isolation wall 1202 and the respective utility walls 1203 and 1205 is provided with insulation 1206 (e.g., 3 inch (7.62 cm) compressed semi-rigid mineral wool batt insulation, field-finished and installed). Corresponding gaskets 1210 are placed in the interface areas.

[0083] Beam covers 1216 (e.g., carbon foam beam covers) are placed on the ends of the corbel beams 1212. Weather barriers 1224 are factory-installed on the substrate at the ends of the separation wall 1202. Shims 1222 can be used, if necessary, to ensure a good fit between the separation wall 1202 and the utility walls 1203 and 1205. Weather barriers 1218 can be factory-installed on the substrate above the utility walls 1203 and 1205. Closures 1220 can be factory-installed on the outside of each of the utility walls 1203 and 1205 above the weather barriers 1218.

[0084] Figure 13 is a cross-sectional view of an exemplary separation wall and window wall interface, according to some implementations. In particular, Figure 13 shows details of the interface between a separation wall 1330 and two window walls 1331, 1333. The separation wall 1330 is supported by a lower corbel beam 1326. The corbel beam 1326 is connected to a wide-flange steel column 1303 via a corbel beam connection 1327, as described in more detail herein in connection with Figure 9. The balcony beam 1302 is also shown connected to the wide-flange steel column 1303. Figure 13 also shows the contour 1328 of the lower floor panel and the trailing edge of the floor panel recess 1332.

[0085] Each window wall 1331 and 1333 includes a window jamb assembly 1316 (e.g., a field-installed window jamb assembly having a ¼-inch (0.64 cm) board screwed to the separation wall 1330 using #10 x 3-inch (7.62 cm) flathead screws through sealed pre-drilled holes), a sliding door 1318 (field-installed), shims 1314 and / or 1320 (field-installed) as needed, and a snap-in jamb filler 1322 (field-installed). Sealant and backer rods 1310 and 1334 are installed at the joints between each window wall 1331 and 1333 and each side of the separation wall 1330. The window walls 1331 and 1333 also include factory-installed flashings 1308 and 1312, respectively. The flashing 1308 and 1312 may comprise a 1 / 8 inch (0.32 cm) pultruded fiber reinforced polymer material.

[0086] Figure 14 is a cross-sectional view of an exemplary end wall / utility wall corner according to some embodiments. In particular, Figure 14 shows a corner where an end wall 1402 (e.g., similar to 500) meets a utility wall 1408 at the corner. The outline of a floor panel 1410 is shown at the corner. A corbel beam 1422 supports the end wall 1402, and the corbel beam 1422 is connected to a wide-flange corridor beam 1420 via a corbel beam plate connection 1424 (e.g., as described herein in connection with Figure 9). The wide-flange corridor beam 1420 is connected to a wide-flange column 1405, which is connected to a wide-flange beam 1404 (below).

[0087] The corbel beam 1422 supports the end wall 1402, which is disposed on the corbel beam 1422. The end wall 1402 includes an end wall closure 1422 (e.g., a 1 / 4 inch (0.64 cm) pultruded fiber reinforced polymer closure that is factory attached to the end wall 1402).

[0088] The space between the end wall 1402 and the utility wall 1408 contains first insulation 1406 (e.g., 3-inch (7.62 cm) compressed semi-rigid mineral wool batt insulation, field-finished), a utility wall gasket 1412 (e.g., a gasket on the utility wall configured to contact a corresponding gasket on the end wall 1402), second insulation 1414 (e.g., 2-inch (5.08 cm) semi-rigid mineral wool batt insulation board factory-bonded to the utility wall 1408), and a closure 1416 (e.g., a factory-installed aluminum closure).

[0089] Figure 15 is a cross-sectional view of an exemplary end wall of a window wall according to some embodiments. In particular, Figure 15 shows an end wall 1518 attached to a cantilever beam 1526 (to a corbel beam, not shown, below the end wall 1518) via a corbel beam connection 1528. The cantilever beam 1526 is connected to a wide-flange steel column 1524, which is connected to a wide-flange beam 1520. The end wall 1518 meets the window wall 1530 at a corner. The outline of a floor panel 1516 is shown at the corner.

[0090] The end wall 1518 includes a closure 1504 (e.g., a factory-installed 1 / 4 inch (0.64 cm) pultruded FRP closure) and an exhaust vent 1502 (e.g., factory-installed on the closure 1504). One or more shims 1510 are used as needed to align the closure 1504 on the end wall 1518. The window wall 1530 includes flashing 1508 (e.g., factory-installed 1 / 8 inch (0.32 cm) pultruded FRP flashing). A sealant and backer rod 1514 are used to seal the joint where the window wall 1530 and the end wall 1518 meet. Figure 15 also shows the rear edge of the recess 1512 in the floor panel.

[0091] Figure 16 is a cross-sectional view of an exemplary window wall in a floor panel according to some embodiments. In particular, Figure 16 shows details of the intersection where an upper window wall 1648 and a lower window wall 1652 meet the floor panel 1650. Also shown is a balcony 1610 (e.g., a 4-inch (10.16 cm) lightweight precast concrete balcony) supported by balcony beams 1622. The balcony 1610 is attached to the balcony beams 1622 via anchors 1646 embedded in the concrete of the balcony 1610. The balcony 1610 serves as the balcony for the unit corresponding to the upper window wall 1648.

[0092] A sliding door (or window) sill assembly 1602, shimmed as necessary, is factory bonded to a floor panel 1650 over pan flashing 1604 (e.g., factory-installed, pre-sloped 1 / 8 inch (0.32 cm) FRP pultruded pan flashing). Primary insulation 1606 (e.g., 2 inches (5.08 cm) rigid insulation) is factory bonded to the edge of the floor panel 1650. Trim 1608 (e.g., 1 / 4 inch (0.64 cm) pultruded FRP trim) is placed over the primary insulation 1606.

[0093] Window walls 1648 and 1652 each include field-installed sliding doors 1612 and 1636. At the base of sliding door 1612 are back legs and end dams 1614 and sill trim 1616 (e.g., stainless steel sill trim coated with a sealant and installed with a field finish).

[0094] J-channels 1624 are factory installed on the bottom edge of the primary insulation 1606. The J-channels 1624 may comprise 2-inch (5.08 cm) J-channels with 2-inch (5.08 cm) and 3-inch (7.62 cm) legs with 1 / 4-inch (0.64 cm) diameter weeps pre-punched on 48-inch (121.92 cm) centers (OC). Sealant on bond break tape 1626 is installed at the field finish.

[0095] A vent opening 1628 with insect protection is installed at the factory. A window head 1630 (e.g., a window head with a baffled trickle vent extrusion) is installed at the factory to the bottom of the floor panel 1650 using fasteners 1632 (e.g., #10 x 3 / 4 inch (1.91 cm) washer-equipped screws). The trickle vent is provided with a free area opening 1642 (e.g., a 20 square inch (129.03 square cm) net free area opening in the trickle vent is installed at the factory).

[0096] The floor panel 1650 includes sheet metal 1644 (e.g., 22ga x 19 inch (48.26 cm) steel sheeting attached to three first joists using #10 x 1 inch (2.54 cm) FHSD on 24 inch (60.96 cm) centers). The floor panel 1650 also includes second insulation 1634 (e.g., full cavity 3-1 / 2 inch (8.89 cm) semi-rigid mineral wool batt insulation to the third joist, factory installed). Window blinds 1638 are field-finished and installed adjacent to the interior side of the window wall 1652. Sealant and backer rods 1640 are installed above the window head 1630 adjacent to the window blinds 1638.

[0097] Figure 17 is a cross-sectional view of an exemplary end wall of a floor panel according to some embodiments. In particular, Figure 17 shows details of the area where an upper end wall 1758, a floor panel 1760, and a lower end wall 1762 meet at a corbel 1722. Also shown in Figure 17 are structural members including wide flange beams 1748 and wide flange columns 1756 (e.g., without fireproofing).

[0098] The top wall 1758 is provided with C-channel metal track 1702 (e.g., 3-5 / 8 inch (9.21 cm) by full length C-channel 18 ga metal track with knockouts at the stud locations, factory installed). At the interface between the top wall 1758 and the corbel 1722 is installed first insulation 1704 (e.g., 4 inch (10.16 cm) by 1 / 4 inch (0.64 cm) ceramic fiber insulation glued to the bottom surface of the top wall 1758).

[0099] In the space where the top wall 1758 meets the floor panel 1760, behind the base plate, is installed secondary insulation 1706 (e.g., 1-1 / 2 inch (3.81 cm) semi-rigid mineral wool batt insulation, field-installed).

[0100] First angle iron 1708 comprises two angle iron pieces riveted together (e.g., a 1-3 / 4 inch (4.45 cm) x 3 inch (7.62 cm) x 14 ga L-angle attached via rivets to a 3 inch (7.62 cm) x 3 inch (7.62 cm) x 12 ga L-angle, spaced 12 inches (30.48 cm) on center and a maximum of 1 / 2 inch (1.27 cm) from the edge, factory installed). The two angle iron pieces are attached to top wall 1758 and floor panel 160 via fasteners 1710. One of the angle iron pieces is welded to corbel beam 1722 via weld 1712. Top wall 1758 comprises a base panel bracket and / or base panel 1714 that are installed in the field.

[0101] A second angle iron member 1716 (e.g., a 2-inch (5.08 cm) x 2-inch (5.08 cm) x 1 / 8-inch (0.32 cm) x 23' 4" (711.20 cm) L-angle) is welded to the interior side of the corbel beam 1722 at weld 1720 to support the floor panel 1760. A third angle iron 1718 (e.g., a 1-1 / 4-inch (3.18 cm) x 2-inch (5.08 cm) x 18 ga L-angle) is bonded to the underside of the second angle iron member 1716 (e.g., field-finished attached via a 1-inch (2.54 cm) very high bond tape). The third angle iron is bonded to an upper interior finish plate 1772 of the bottom wall 1762.

[0102] Plates 1728 (e.g., 1 / 8 inch (0.32 cm) by 2-1 / 2 inch (6.35 cm) by 23' 4 inch (711.20 cm) steel plates) are welded to each side of the corbel beam 1722. In some implementations, the plates 1728 can have 2-1 / 2 inch (6.35 cm) legs and 1 inch (2.54 cm) vertical slot holes every 24 inches (60.96 cm) on centers, starting 8 inches (20.32 cm) from the edge of the angle and 3-1 / 2 inches (8.89 cm) from the bottom of the angle. The top of the bottom end wall 1762 is attached to the corbel beam 1722 via the plates 1728. Fasteners 1726 are inserted through vertical slots in board 1728 into the gypsum board and steel sheet layers of end wall 1726 (see, e.g., the description of Figure 5 above for details on the layers of end wall 1726). One or more shims 1730 can be used, if necessary, to ensure a tight fit of the lower end wall 1762. Third insulation 1732 (e.g., 3-inch (7.62 cm) mineral wool insulation) is installed on the interior wall panels 1758 and 1762 between the gypsum layer and the interior finish panel layer. Fourth insulation 1746 (e.g., 1-1 / 2-inch (3.81 cm) x 4-inch (10.16 cm) semi-rigid mineral wool insulation board factory-bonded to the top of the end wall) is installed on top of end wall 1746.

[0103] Shown within end wall 1762 is sprinkler pipe 1754. One or more end walls can be equipped with sprinkler pipe 1754. Gasket 1752 (e.g., a silicone gasket) is factory installed at the connection between the exterior finish panel of end wall 1762 and the weather barrier.

[0104] The corbel beam 1722 comprises a hollow structural section (HSS) beam (or tube steel beam) 1770 (e.g., a 16 inch (40.64 cm) by 8 inch (20.32 cm) by 5 / 16 inch (0.79 cm) hollow structural HSS beam) that encloses a wide flange beam 1766 and a plate 1768. The space within the hollow structural HSS beam 1770 is filled with grout 1764 (e.g., fire-resistant). The tube steel 1770 surrounding the beam 1766 acts as a form for the grout 1764 and is used to attach floor panels, end walls, etc. to the corbel beam 1722 (e.g., by welding angle iron or plate to the hollow structural HSS beam 1770, which is then connected to the end walls, floor panels, etc.).

[0105] Trim pieces 1744 (e.g., ¼-inch (0.64 cm) pultruded FRP trim) are factory-bonded to the corbel beams 1722. The trim 1744 includes one or more weeps 1750 (e.g., factory-installed on 24-inch (60.96 cm) centers). Plates 1740 are bonded to the corbel beams 1722 (e.g., welded at 1742). The plates 1740 bond the corbel beams 1722 to the top wall 1758. In the interior space where the trim 1744 extends behind the exterior wall panel of the top wall 1758, flashing 1736 (e.g., pultrusion members) and sealant 1738 (e.g., non-setting butyl sealant) are factory-installed. A weather-resistant barrier 1734 is factory-installed over the flashing 1736.

[0106] 18 is a cross-sectional view of an exemplary utility wall in a floor panel according to some embodiments. In particular, FIG. 18 shows details of the area where two exterior utility walls, an upper exterior utility wall 1842 and a lower exterior utility wall 1846, meet, where floor panel 1844 meets upper exterior utility wall 1842.

[0107] The upper utility wall 1842 includes a first angle iron 1802 (e.g., 2-1 / 2 inch (6.35 cm) x 5 inch (12.7 cm) x 3-3 / 4 inch (9.53 cm) angle iron, factory installed) coupled to the upper utility wall 1842 and metal stud blocking 1804 (e.g., 4 inch (10.16 cm) metal stud blocking between vertical utility wall studs, factory installed) coupled to the upper utility wall 1842 via the utility wall studs.

[0108] A second angle iron 1812 (e.g., a 3-inch (7.62 cm) x 3-inch (7.62 cm) x 12 ga L-angle, installed at the factory) is coupled to the upper utility wall 1842 and metal stud blocking 1804 at the factory via fasteners 1806 (e.g., #10 x 1-inch (2.54 cm) hex head self-drilling screws installed at the factory, every 6 inches (15.24 cm) on center into pre-drilled holes). The second angle iron 1812 is attached to the floor panel 1844 via fasteners 1814 (e.g., #10 x 1-inch (2.54 cm) hex head self-drilling screws installed at the factory, every 6 inches (15.24 cm) on center into pre-drilled holes). The upper utility wall 1842 also includes base plate brackets 1808 for supporting an interior base plate 1810.

[0109] The floor panels 1844 are provided with metal track 1816 (e.g., 12-inch (30.48 cm) 14-gauge metal track coped at the ends, factory installed). Primary insulation 1820 (e.g., ½-inch (1.27 cm) by 4-inch (10.16 cm) semi-rigid mineral wool batt insulation, field-finished and installed) is installed where the ends of the floor panels 1844 meet the upper utility wall 1842.

[0110] A third angle 1818 (e.g., a 2 inch (5.08 cm) x 2 inch (5.08 cm) x 18 ga metal L-angle) is attached to the bottom furring of the floor panel (e.g., via a 1 inch (2.54 cm) very high bond tape, finished in place). The interior top panel of the lower utility wall 1846 is attached to the third angle 1818 via fasteners.

[0111] Sprinkler pipe 1822 is positioned between the interior underlayment of lower utility wall 1846 and the lower utility wall 1846 top panel. Hat channels 1824 and 1832 connect the finish panel of lower utility wall 1846 to the underlayment and sheet metal layer of lower utility wall 1846. Secondary insulation 1826 (e.g., 2-1 / 2 inch (6.35 cm) semi-rigid mineral wool batt insulation) is field-installed where upper utility wall 1842 meets lower utility wall 1846. Riser-to-riser connection 1828 is field-installed to connect factory-installed waste and vent pipes 1848 and 1834 (e.g., 4 inch (10.16 cm) pipe) within upper utility wall 1842 and lower utility wall 1846, respectively. A fire-stopping caulk seal 1830 is factory installed at the opening where the waste and vent pipe 1834 exits the substrate of the lower utility wall 1846 .

[0112] Also shown in Figure 18 is a floor assembly 1836 (e.g., for the hallway walkways between units) comprising 3.25 inch lightweight concrete with a 2-hour rating on a 2 inch (5.08 cm) metal pan deck. The floor assembly 1836 is supported by hallway beams 1838 connected to structural columns 1840.

[0113] Figure 19 is a cross-sectional view of an exemplary corbel beam 1924 at the junction of a floor panel and a separation wall, according to some embodiments. Specifically, Figure 19 is a cross-sectional view of an exemplary corbel beam 1924 at the junction where a first floor panel 1942, a second floor panel 1944, a first separation wall 1946, and a second separation wall 1948 meet.

[0114] The first separation wall 1946 has first fasteners 1902 (e.g., #2 Phillips with #8 x 1-5 / 8 inch (4.13 cm) wafer head drill points on 24 inch (60.96 cm) centers into steel sheeting) that attach the hat channels 1950 to the separation wall. The first fasteners 1902 extend through the gypsum substrate and the sheet metal. Angle iron 1904 (e.g., 1-3 / 4 inch (4.45 cm) x 3 inch (7.62 cm) x 14 ga attached to 3 inch (7.62 cm) x 3 inch (7.62 cm) x 12 ga angle iron welded to corbel beam 1924 at welds 1914) is installed on each side of the bottom of first separation wall 1946 where first separation wall 1946 meets corbel beam 1924 (e.g., attached to the 3 inch (7.62 cm) x 3 inch (7.62 cm) angle iron using screws), and angle iron 1904 is coupled to first separation wall 1946 via fasteners 1906 (e.g., #2 Phillips with #8 x 1-5 / 8 inch (4.13 cm) wafer head drill points to studs every 24 inches (60.96 cm) on center). Floor panel 1942 and floor panel 1944 are attached to angle iron coupled to corbel beam 1924 using fasteners 1908 (for example).

[0115] C-channel metal track 1910 (e.g., 3-5 / 8 inch (9.21 cm) x 8 foot (243.84 cm) 18 ga metal track with knockouts at the stud locations) is installed at the factory. Primary insulation 1912 (e.g., 4 inch (10.16 cm) x 1 / 4 inch (0.64 cm) ceramic fiber insulation) is factory bonded to the bottom of the separation wall 1946. The separation wall includes a base plate 1916 (e.g., a 5 mm aluminum composite base plate).

[0116] A spacer 1918 (e.g., a ½ inch (1.27 cm) × 3 inch (7.62 cm) × 4 inch (10.16 cm) spacer) is factory-installed on only one side of the corbel beam. Angle iron 1922, 1930 is welded to the corbel beam 1924 (e.g., at weld 1920). A pair of plates 1926 is welded to either side of the bottom of the corbel beam 1924 (e.g., at weld 1934) and connects a second separation wall 1948 to the corbel beam 1924 via fasteners 1936. Second insulation 1938 is factory-installed on top of the second separation wall 1948. One or more shims 1928 can be used to align the separation wall 1948 for connection to the corbel beam 1924. Also, a fire sprinkler pipe 1940 is factory-installed near the top of the second separation wall 1948. The upper portion of the separating wall 1948 is provided with a closure 1932 on either side.

[0117] Figure 20 is a cross-sectional view of an example floor panel-to-floor panel connection, according to some embodiments. In particular, Figure 20 shows a connection 2002 where an intermediate floor panel 2016 (e.g., a floor panel that is not adjacent to a window wall or utility wall) abuts a window floor panel 2018. A first metal connection member 2006 is secured to a second metal connection member 2008 via one or more fasteners 2004. The first metal connection member 2006 and the second metal connection member 2008 can comprise 16 ga Fy=50 ksi (344.7 MPa) flexural CFS 3 / 4 inch (1.91 cm) x 2 inch (5.08 cm) with pre-punched holes. Insulation 2010 (e.g., 1 inch (2.54 cm) semi-rigid mineral wool insulation board compressed to 3 / 4 inch (1.91 cm) glued to the window floor panel, installed at the factory) is placed in the space between the two floor panels 2016 and 2018. Metal angles 2012 are bonded to the joists of the window floor panel at the factory. Fire tape 2014 is installed at the factory.

[0118] Figure 21 is a cross-sectional view of an exemplary floor panel according to some implementations. In particular, Figure 21 shows a connection 2102 where an intermediate floor panel 2118 (e.g., a floor panel that is not adjacent to a window wall or a utility wall) abuts a utility wall floor panel 2116. A first metal connection member 2106 is fastened to a second metal connection member 2108 via one or more fasteners 2104. The first connection member 2106 and the second connection member 2108 can comprise 16 ga Fy=50 ksi (344.7 MPa) flexural CFS 3 / 4 inch (1.91 cm) x 2 inch (5.08 cm) with pre-punched holes. Insulation 2110 (e.g., 1 inch (2.54 cm) semi-rigid mineral wool insulation board compressed to 3 / 4 inch (1.91 cm) glued to an intermediate panel, installed at the factory) is placed in the space between the two floor panels 2116 and 2118. Metal angles 2112 are bonded to the joists of the intermediate panels at the factory. Fire tape 2114 is installed at the factory.

[0119] Figure 22 is a cross-sectional view of an exemplary interior hallway according to some embodiments. In particular, Figure 22 shows a hallway floor 2202 (e.g., a 2-hour rated floor assembly comprising a 3.25-inch lightweight concrete slab on a 2-inch (5.08 cm) metal pan deck) supported by hallway joists 2204 and 2206 attached at each end to columns (e.g., 2208 and 2210, one end).

[0120] 23A and 23B show an exemplary utility wall connection according to some embodiments. FIG. 23A is a cross-sectional view of the connection between an upper utility wall 2306 and a lower utility wall 2308. One or more boards 2302 (e.g., 8-inch (20.32 cm) x 8-inch (20.32 cm) x 18 ga boards on 24-inch (60.96 cm) centers) are used to join the upper utility wall 2306 and the lower utility wall 2308. The boards 2302 are joined to the utility walls (2306 and 2308) using fasteners 2304. FIG. 23B is an elevation view of the connection between two utility wall panels (2306 and 2308).

[0121] FIG. 24 shows an exemplary corbel connection at a separation wall and end wall, according to some implementations. FIG. 24 shows a closure 2402 of a wall and floor panel (end indicated at 2404) supported by a corbel 2408 (e.g., similar to 1722 in FIG. 17 ). The end of the corbel includes a cap plate 2414 (e.g., a ½-inch (1.27 cm) plate cut to fit the inside radius of the hollow structural HSS of the corbel 2408, ⅛-inch (0.32 cm) shorter on all sides, factory-installed), insulation 2406 (e.g., ½-inch (1.27 cm) insulation, factory-installed), and an end plate 2412 (e.g., 5 / 8-inch (1.59 cm) by 8-inch (20.32 cm) by 16-inch (40.64 cm), factory-installed). The end plate 2412 is coupled (e.g., bolted) to a cap plate 2414 and a connecting plate 2416 (e.g., a 3 / 4 inch (1.91 cm) by 6-1 / 8 inch (15.56 cm) by 15 inch (38.1 cm) plate with five 1 inch (2.54 cm) diameter holes).

[0122] The connecting plate 2416 is bolted to the shear tabs 2428 using five 1 inch (2.54 cm) bolts 2430. The shear tabs 2428 are bonded to the column flanges 2420 and web 2418. Stiffeners 2424 are bonded to the column above and below the shear tabs 2428. A plate 2426 is bonded to the column flange 2420 on each side where the shear tabs 2428 are bonded to the column. Balcony beams 2422 are shown beyond the columns.

[0123] FIG. 25 shows an exemplary corbel beam in a separation wall and utility wall, according to some embodiments. FIG. 25 shows a wall closure 2502 supported by a corbel beam 2506 (e.g., similar to 1722 in FIG. 17). The end of the corbel beam 2506 includes a cap plate 2410 (e.g., a ½ inch (1.27 cm) plate cut to fit the inside radius of the hollow structural HSS of the corbel beam 2506, ⅛ inch (0.32 cm) shorter on all sides, factory installed), insulation 2504 (e.g., ½ inch (1.27 cm) insulation, factory installed), and an end plate 2530 (e.g., 5 / 8 inch (1.59 cm) by 8 inch (20.32 cm) by 16 inch (40.64 cm), factory installed). End plate 2530 is coupled (e.g., bolted) to cap plate 2510 and connecting plate 2524 (e.g., a 3 / 4 inch (1.91 cm) by 6-1 / 8 inch (15.56 cm) by 15 inch (38.1 cm) plate with five 1 inch (2.54 cm) diameter holes).

[0124] The connecting plate 2524 is bolted to shear tabs 2528 using five 1 inch (2.54 cm) bolts 2526. The shear tabs 2528 are bonded to the column flange 2514 and web 2512. Stiffeners 2518 are bonded to the column above and below the shear tabs 2528. The plate 2520 is bonded to the column flange 2514 on each side where the shear tabs 2528 are bonded to the column. Corridor beams 2516 are shown beyond the columns.

[0125] Figure 26 shows an exemplary corbel beam in an end wall and window wall according to some embodiments. Figure 26 shows a closure 2602 of wall and floor panels (edge ​​indicated at 2604) supported by a corbel beam 2608 (e.g., similar to 1722 in Figure 17). The end of the corbel beam is equipped with a cap plate 2614 (e.g., a ½ inch (1.27 cm) plate cut to fit the inside radius of the hollow structural HSS of the corbel beam 2608, ⅛ inch (0.32 cm) shorter on all sides, factory installed), insulation 2606 (e.g., ½ inch (1.27 cm) insulation, factory installed), and an end plate 2412 (e.g., 5 / 8 inch (1.59 cm) by 8 inch (20.32 cm) by 16 inch (40.64 cm), factory installed). The end plate 2612 is coupled (e.g., bolted) to a cap plate 2614 and a connecting plate 2616 (e.g., a 3 / 4 inch (1.91 cm) by 6-1 / 8 inch (15.56 cm) by 15 inch (38.1 cm) plate with five 1 inch (2.54 cm) diameter holes).

[0126] The connecting plate 2616 is bolted to shear tabs 2628 using five 1 inch (2.54 cm) bolts 2630. The shear tabs 2628 are bonded to the column flange 2620 and web 2618. Stiffeners 2624 are bonded to the column above and below the shear tab 2628. A plate 2626 is bonded to the column flange 2620 on each side where the shear tabs 2628 are bonded to the column. Balcony beams 2622 are shown beyond the columns.

[0127] Figure 27 illustrates an exemplary entry door section in a utility wall, according to some embodiments. In particular, Figure 27 shows hallway floors (2702-2706) supported by corresponding hallway beams (2708-2712). The utility walls (2714-2718) are shown in relation to corresponding entry doors (2720-2722) that lead to units (e.g., apartment units, etc.). Inside each unit, corresponding to the entry door, are floor panels (2724-2728).

[0128] 28 is a plan view of an exemplary entry door in a utility wall according to some implementations. In particular, FIG. 28 shows a first utility wall 2802 (e.g., similar to 600), a second utility wall 2804, and an entry door 2806. Details of the door jamb are shown in FIG. 29.

[0129] FIG. 29 shows details of an exemplary entry door jamb according to some implementations. In particular, FIG. 29 illustrates a door jamb 2912 (e.g., a factory-installed, rated door jamb secured to a utility wall panel 2922 using #10 screws every 24 inches (60.96 cm) on center) with solid wood applied stops 2908 (e.g., solid wood stops installed at the factory using 1-1 / 2 inch (3.81 cm) finish nails every 12 inches (30.48 cm) on center) and shims 2910 (e.g., to ensure the door jamb fits tightly against the utility wall 2922, if necessary). Door 2906 (e.g., a rated entry door) is shown meeting stop 2908.

[0130] The trim 2904 can be installed in the field. Sealant and backer rod can be applied to the gap between the interior 2902 and exterior 2916 where the door jamb assembly meets the utility wall 2922. The lower door threshold is indicated by line 2914. At the exterior corner of the utility wall 2922, outside of the door jamb assembly, a closure panel 2918 (e.g., an aluminum composite closure panel) is attached to the utility wall 2922 (e.g., using extruded aluminum vertical furring strips). Decorative steel sheeting 2920 can be installed in the field to finish the threshold.

[0131] FIG. 30 illustrates exemplary ceiling access door blocking according to some embodiments. In particular, FIG. 30 illustrates 12-inch (30.48 cm) metal joist blocking 3002 and 3012 spanning between metal floor joists 3004. The floor joists may have other spacings, such as 10 inches (25.4 cm), and blocking 3002 and 3012 would be sized accordingly. A ceiling access door 3006 (e.g., an 8-inch (20.32 cm) by 8-inch (20.32 cm) ceiling access door) is installed below a shower drain 3008 that is connected to a drain pipe 3016. The ceiling access door 3006 is installed within a frame formed by the blocking and joists, which are connected at the corners by one or more clips 3010 (e.g., 1-1 / 2 inch (3.81 cm) x 7-1 / 2 inch (19.05 cm) x 20 ga) secured to the joists and blocking at the factory. A metal cover 3014 (e.g., 1-1 / 2 inch (3.81 cm) x 1-1 / 2 inch (3.81 cm) x 20 ga) can be attached to the joists and blocking via one or more clips (e.g., 1-1 / 2 inch (3.81 cm) x 1-1 / 2 inch (3.81 cm) x 20 ga clip angles attached via screws at the factory). The ceiling access door 3006 provides access to the shower drain area from the unit below where the shower is located.

[0132] FIG. 31 illustrates an exemplary shower drain and ceiling access door, according to some embodiments. In particular, a shower drain 3102 (factory installed) is coupled to a shower pan 3104. A fire stop 3106 (e.g., a 2-hour fire stop) is installed in a pipe penetration through the floor. A drain pipe 3108 is coupled to the shower drain 3102 and leads to a utility wall. Steel joists (e.g., 3110) are installed in the floor panels (e.g., every 10 inches (25.4 cm) center or every 12 inches (30.48 cm) center). Openings 3114 are cut in the joists to allow the drain pipe 3108 to pass through. Metal blocking 3112 (e.g., 10-inch (25.4 cm) wide metal blocking) and 3122 are installed for attachment of an access door 3120. The access door 3120 may comprise a 90 minute rated access door that is factory fixed to the floor joists 3110 and blocking 3112, 3122. Beneath the floor panels, ceiling panels 3116 are installed with field finish and light fixture rails 3118 are installed at the factory.

[0133] FIG. 32 shows an exemplary utility wall at a unit entry door according to some embodiments. In particular, FIG. 32 shows a door and frame 3202. Decorative steel sheeting 3204 (e.g., 1 / 8 inch (0.32 cm) decorative steel sheeting installed in a bed of sealant with a maximum slope of 2%, field-finished installation). A metal door threshold 3206 is field-finished installed on top of the decorative steel sheeting 3204. Sealant 3208 is applied to the joint between the floor panel and the utility wall. Shims 3210 can be installed as needed for flush installation of the finished floor. Insulation 3212 (e.g., 1 / 2 inch (1.27 cm) semi-rigid mineral wool insulation glued to the floor panel) is factory-installed in the floor panel.

[0134] The top of the entry door jamb is shown at the bottom of the utility wall. The connection between the top of the entry door jamb and the bottom of the utility wall is field-finished with a sealant and backer rod 3214. Wood trim 3216 is field-finished and installed. The rated door jamb 3218 is field-finished and secured to the wall panel. The rated door 3220 is shown.

[0135] The exterior of the utility wall is fitted with metal panel closures and vertical aluminum furring strips 3228. Porous insect screens 3226 are factory installed on the utility wall panels. Angle iron 3224 (e.g., 5 in. (12.7 cm) x 4 in. (10.16 cm) x 16 ga L-angles) is attached to the utility wall at the floor opening to support the edge of the hallway floor. At the upper entry door, a closure panel 3222 (e.g., aluminum composite panel, factory installed) is installed.

[0136] 33 illustrates an exemplary bedroom wall door jamb according to some embodiments. In particular, the bedroom wall door jamb includes a solid wood door 3304, a solid wood stop 3302 attached to the wood jamb 3306, a shim 3308 (optional), and a bedroom wall 3310.

[0137] Figure 34 is a cutaway view of an exemplary separation wall 3402, according to some embodiments. Figure 35 is an exploded view of the components and component arrangement of the exemplary separation wall 3402 of Figure 34, according to some embodiments. Separation wall 3402 includes glass mat furring board 3501, semi-rigid mineral wool batt insulation 3502, glass mat furring board 3503, glass mat furring board 3504, wall box light fixture 3505, glass mat furring board 3506, and wall box light fixture 3507. The utility wall 3402 also includes a ventilation fan housing 3508, a microwave exhaust duct 3509, glass mat base boards 3510-3512, semi-rigid mineral wool batt insulation 3513, a steel plate 3514, a bent plate 3515, a sprinkler pipe 3516, glass mat base boards 3517-3518, semi-rigid mineral wool insulation 3519, a track 3520, a steel plate 3521, a glass mat base board 3522, semi-rigid mineral wool batt insulation 3523, a glass mat base board 3524, a steel plate 3525, and insulation 3526.

[0138] Separation wall 3402 further includes glass mat base board 3527, weather resistant barrier 3528, separation wall cover 3529, weather resistant barrier 3530, glass mat base board 3531, ceramic fiber insulation 3532, steel sheet 3533, glass mat base board 3534, hat channels 3535-3538, armored cable 3539-3540, quad outlet wall box 3541, shade driver wall box 3542, low voltage wall box 3543, armored cable 3544, CAT6 jumper 3545, quad outlet wall box 3546, armored cable 3547, double wall box 3548, armored cable 3549, double wall box 3550, and dishwasher outlet wall box 3551. Utility wall 3402 further includes armored cables 3552-3554, double wall box 3555 with outlet and waste switch, range wall box 3556, pipe straps 3557, conduit straps 3558, double wall box 3559, pipe straps 3560, pex pipe 3561, armored range cable 3562, armored cable 3563, armored cables 3564-3565, pipe straps 3566, and plumbing subassemblies 3567 (e.g., sink drains and vents).

[0139] Separation wall 3402 further includes double walled box 3568, armored cable 3569, low voltage wiring 3570, hat channels 3571-3573, glass mat base board 3574, insulation 3575, glass mat base board 3576, weather resistant barrier 3577, semi-rigid mineral wool batt insulation 3578, separation wall cover 3579, studs 3580, semi-rigid mineral wool batt insulation 3581, insulation 3582, gasket g-clip 3583, and glass mat base board 3584.

[0140] Figure 36 is a cutaway view of an exemplary end wall 3602, according to some embodiments. Figure 37 is an exploded view of the exemplary end wall 3602 of Figure 36, according to some embodiments. End wall 3602 includes sprinkler pipe 3701, end wall edge flashing 3702, ACM panels 3703, vertical aluminum furring strips 3704, ACM panels 3705, vertical aluminum furring strips 3706, weather barrier 3707, vertical aluminum furring strips 3708, ACM panels 3709, vertical aluminum furring strips 3710-3711, bent plate 3712, insulation 3713, vertical aluminum furring strips 3714, ACM panels 3715, vertical aluminum furring strips 3716, weather barrier 3717, and insulation 3718-3719.

[0141] Also, the end wall 3602 is made of insulation 3720, ACM panel 3721, steel plate 3722, ACM panel 3723, insulation 3724, glass mat base board 3725, weather resistant barrier 3726, end wall cover 3727, R stud 3728, track 3729, ceramic fiber insulation 3730, track 3731, steel plate 3732, stud 3734, semi-rigid mineral wool batt insulation 3735, steel plate 3736, insulation 3737, glass mat base board 3738, hatch Channel 3739, quad outlet wall box 3740, armored cable 3741-3742, shade driver wall box 3743, hat channel 3744, CAT6 jumper 3745, armored cable 3746, quad outlet wall box 3747, armored cable 3748, double wall box with data 3749, low voltage wall box 3750, armored cable 3751, dishwasher quad wall box 3752, and double wall box 3753.

[0142] End wall 3602 further includes armored cable 3754, armored cable 3755, duplex / disposable switch wall box 3756, range duplex wall box 3757, pipe strap 3758, duplex wall box 3759, duplex wall box 3760, pipe strap 3761, Pex pipe 3762, piping subassembly 3763 (e.g., sink drain and vent, cast iron), armored cable 3764-3767, conduit strap 3768, hat channels 3769-3770, armored cable 3771, low voltage cable 3772, hat channels 3773-3774, microwave exhaust duct 3775, hat channel 3776, gasket g-clip 3777, glass mat underlay board 3778, insulation 3779, and steel plate 3780. It includes semi-rigid mineral wool insulation 3781, studs 3782, glass mat base board 3783, end wall cover 3784, semi-rigid mineral wool batt insulation 3785, weather resistant barrier 3786, glass mat base board 3787, insulation 3788, semi-rigid mineral wool insulation board 3789, and track 3790.

[0143]

[00137] Figure 38 is an isometric view of an exemplary intermediate floor panel 3802 according to some implementations. Figure 39 is an exploded view of the exemplary intermediate floor panel 3802 of Figure 38 according to some embodiments. In particular, the intermediate floor panel 3802 includes hydronic aluminum sheets 3901-3903, hydronic foams 3902 and 3942, cement board 3904, steel sheet 3905, angle iron 3906-3907, track 3908, bent metal member 3909, semi-rigid mineral wool insulation 3910, glass mat base board 3911, FRP light fixture clips 3912, steel sheet 3913, glass mat base board 3914, blocking 3915, FRP light fixture clips 3916, and angle iron 3917.

[0144] Intermediate floor panel 3802 also includes eye bolts 3918-3919, joists 3920, glass mat base boards 3921-3923, FRP light fixture clips 3924, screws 3925, semi-rigid mineral wool batt insulation 3926, glass mat base board 3927, semi-rigid mineral wool batt insulation 3928-3933, angle iron 3934-3935, track 3936, angle iron 3937, joist 3938, bent metal 3939, joist 3940, cement board 3941, hydronic foam 3942-3943, hydronic aluminum sheet 3944, cement boards 3945-3948, quad outlet floor box 3949, and cement boards 3950-3951.

[0145] Figure 40 is an isometric view of an exemplary bathroom floor panel 4002, according to some embodiments. Figure 41 is an exploded view of the exemplary utility wall floor panel 4002 of Figure 40, according to some embodiments. The utility wall floor panel 4002 includes a shower pan 4101, a shower base support 4102, hydronic aluminum sheets 4103-4104, hydronic foam 4105, cement board 4106, angle iron 4107-4108, track 4109, floor joists 4110, track 4111, angle iron 4112, blocking 4113, glass mat furring boards 4114-4115, FRP light fixture clips 4116, an access door 4117, glass mat furring boards 4118, angle iron 4119, and glass mat furring boards 4120.

[0146] The bathroom floor panel 4002 also includes blocking 4121, angle iron 4122, blocking 4123, angle iron 4124, pressure anchor 4125, threaded rod 4126, eye bolt 4127, pressure anchor 4128, glass mat base board 4130, FRP lighting fixture clip 4131, glass mat base board 4132, semi-rigid wool batt insulation 4133, joists 4134, screws 4135-4136, angle iron 4137, screws 4138, semi-rigid mineral wool batt insulation 4139-4140, steel plate 4141, and semi-rigid mineral wool batt insulation 4142.

[0147] Floor panel 4002 further comprises steel plates 4143, semi-rigid mineral wool batt insulation 4144-4146, glass mat underboard board 4147, angle iron 4148-4149, truck 4150, joists 4151, bent metal 4152, steel plates 4153, cement boards 4154-4155, hydronic foam 4156-4158, hydronic aluminum sheet 4159, and cement boards 4160-4166.

[0148] In some implementations, the walls described herein (e.g., utility walls, separation walls, etc.) can have vertical studs within an interior thermal envelope, with the vertical studs and thermal envelope surrounded by an acoustic / fire barrier. Hat channel members are attached to the outer surface of the thermal envelope and provide space for horizontal placement of pipes and modular electrical components. In some two-story wall panels (e.g., utility wall panels), vertical pipes connect between floors through vertical chases. Providing vertical utility runs (e.g., pipes, etc.) within two-story wall panels reduces the number of connections by half compared to single-story connections.

[0149] Additionally, by enclosing the vertical studs and thermal envelope within the sound / fire barrier and relocating utilities to the space between the sound / fire barrier and the finish system, the need for drilling holes in the sound / fire barrier is reduced or eliminated, thereby improving acoustic performance characteristics. Additionally, the finish system may be removable without the use of tools, making inspection and repair of utilities running within the wall in the space provided by the hat channel significantly easier than with traditional construction systems.

[0150] Figure 42 is an isometric view of an exemplary window wall floor panel 4202, according to some embodiments. Figure 43 is an exploded view of the exemplary window wall floor panel 4202 of Figure 42, according to some embodiments. The window wall floor panel 4202 includes cement board 4301, hydronic aluminum sheet 4302, hydronic foam 4303, cement board 4304, steel sheet 4305, track 4306, bent metal 4307, semi-rigid mineral wool batt insulation 4308, glass mat furring board 4309, FRP light fixture clips 4310, eyebolts 4311, hold-down anchors 4312, glass mat furring boards 4313-4315, floor joists 4316, blocking 4317, glass mat furring board 4318, angle iron 4319, glass mat furring board 4320, and glass mat furring board 4321. 0~4321, semi-rigid mineral wool insulation 4322, glass mat base board 4323, semi-rigid mineral wool insulation 4324, glass mat base board 4325, fireproof tape 4326, bent metal 4327, glass mat base board 4328, FRP lighting fixture clip 4329, steel plate 4330, semi-rigid mineral wool batt insulation 4331, angle iron 4332, glass mat base board 4333, semi-rigid mineral wool batt insulation 4334, angle iron 4335, semi-rigid mineral wool batt insulation 4336, angle iron 4337, steel plate 4338.

[0151] Window wall floor panel 4202 also includes track 4339, angle iron 4340, J-channel 4342, semi-rigid mineral wool insulation board 4343, J-channel 4344, floor covering 4345, sheet steel 4346, cement board 4347-4348, Hydonic foam 4349-4350, cement board 4351-4354, quad outlet floor box 4355, and cement board 4356-4357.

[0152] Figure 44A is an isometric view of an exemplary door utility wall panel 4400 according to some implementations. The door utility wall panel shown in Figure 44A spans two floors of a multi-story building, but may be configured to span more or fewer floors of a multi-story building. Figure 44B is an exploded view of the exemplary door utility wall panel of Figure 44A according to some embodiments.

[0153] The door utility wall panel 4400 includes a plurality of aluminum composite panels 4401-4406, 4408-4413, 4415-4417, 4419-4422, 4424-4427, 4429, 4433, 4435, and 4481. The door utility wall panel 4400 also includes a plurality of glass mat backing boards 4407, 4423, 4430, 4432, 4452, 4454, 4702, 4496, 4451, 4492, 4491, 4444, 4441, 4475, 4485, 4706, 4474, 4482, 4490, 4457, 4488, 4456, 4455, and 4489. Door utility wall panel 4400 further includes aluminum vertical furring strips 4414, 4418, 4426, 4428, 4436, 4438, 4439, 4440, 4711, 4710, and 4709. Door utility wall panel 4400 also includes weather-resistant barrier tops 4425 and 4707 and weather-resistant barriers 4431, 4434, 4437, and 4443. Door utility wall panel 4400 further includes gasket elbow 4450, aluminum termination bar 4448, gasket 4703, aluminum termination bar 4704, gaskets 4449 and 4498, and unistrut clamps 4460, 4465, and 4478. The door utility wall panel 4400 also includes hat channel members 4468, 4471, 4472, 4476, 4469, 4483, 4464, 4477, 4461, 4467, and 4487.

[0154] Door utility wall panel 4400 also includes flat stock 4446, angle metal 4470 and 4480, metal flashing 4442, unistruts 4459, 4466, and 4479. Door utility wall panel 4400 further includes insulation 4447, 4705, 4701, 4495, 4445, and 4493. Door utility wall panel 4400 also includes pipe sprinkler 4463, piping riser 4453, piping horizontal assemblies 4462, 4473, and 4484, studs 4494, and tracks 4499.

[0155] Figure 45A is an isometric view of an exemplary kitchen utility wall panel 4500 according to some implementations. The kitchen utility wall panel shown in Figure 45A spans two floors of a multi-story building, but can be constructed to span more or fewer floors of a multi-story building. Figure 45B is an exploded view of the exemplary kitchen utility wall panel 4500 of Figure 45A showing parts and assembly according to some embodiments. Kitchen utility wall 4500 includes metal studs 4501 (e.g., six studs), semi-rigid mineral wool batt insulation 4502, bent metal sheet 4503 (e.g., pre-drilled 3 inch (7.62 cm) x 10 inch (25.4 cm) x 6 inch (15.24 cm) x 0.25 steel), semi-rigid mineral wool batt insulation 4504, track piece 4505, insulation 4506 and 4507 (e.g., self-adhesive backed insulation), glass mat backing board 4508, metal stock 4509, eyebolts 4510, gasket 4511, insulation 4512 (e.g., self-adhesive backed insulation), and glass mat backing board 4513.

[0156] Kitchen utility wall 4500 also includes a weather resistant barrier 4514 (e.g., VaproShield RevealFlashing SA or equivalent), aluminum composite panels 4515 and 4516, aluminum vertical furring strips 4517 and 4518, aluminum composite panels 4519 and 4520, and aluminum vertical furring strips 4521. Kitchen utility wall 4500 further includes an aluminum composite panel 4522, aluminum vertical furring strips 4523, weather resistant barriers 4524, 4525, and 4526 (e.g., VaproShield RevealFlashing SA or equivalent), glass mat backing board 4527, gasket 4528, metal stock 4529, glass mat backing board 4530, and insulation 4531 and 4532 (e.g., self-adhesive backed insulation).

[0157] Kitchen utility wall 4500 also includes blocking member 4533, angle member 4534 (e.g., a 2.5 inch (6.35 cm) x 3.75 inch (9.53 cm) x 5 inch (12.7 cm) x 16 GA steel angle piece), angle member 4535 (e.g., a 4 inch (10.16 cm) x 1 inch (2.54 cm) x 93.75 inch (238.13 cm) x 18 GA steel angle piece), glass mat furring board 4536, hat channel 4537, unistruts 4538 and 4539, pipe sprinkler 4540, and metal angles 4541 and 4555 (e.g., a 3 inch (7.62 cm) x 3 inch (7.62 cm) x 94 inch (238.76 cm) x 12 GA steel angle piece), and glass mat furring board 4542. Kitchen utility wall 4500 further includes modular electrical components 4543-4546, conduit strap 4547, modular electrical components 4548-4549, hat channels 4550 and 4551, pipe sprinkler 4552, unistruts 4553 and 4554, and electrical components 4556-4557.

[0158] Kitchen utility wall 4500 also includes glass mat baseboards 4558 and 4559, 4560 (MM.185), and glass mat baseboard 4561. Figure 46A is an isometric view of an exemplary bathroom utility wall panel 4600 according to some implementations. The bathroom utility wall panel shown in Figure 46A spans two floors of a multi-story building, but can be constructed to span more or fewer floors of a multi-story building. Figure 46B is an exploded view of the exemplary bathroom utility wall panel 4600 of Figure 46A according to some embodiments. The bathroom utility wall panel 4600 includes a glass mat baseboard 4601 and aluminum vertical furring strips (4602, 4603, 4604, 4605, 4607, 4614, 4617, and 4619). The bathroom utility wall panel 4600 also includes aluminum composite panels (4606, 4608, 4609, 4610, 4611, 4612, 4613, 4615, 4618) and a glass mat baseboard 4620.

[0159] Bathroom utility wall panel 4600 further includes metal stock 4621, gasket bottom 4622, unistruts 4623 and 4624, glass mat base board 4625, track 4626, water closet-in-wall tank 4627, tracks 4628-4630, hat channels 4631-4632, and hat channels 4633, 4636, and 4637. Bathroom utility wall panel 4600 further includes hat channels 4634 and 4640, glass mat base board 4641, boards 4635-4638, and metal stock 4639.

[0160] In some of the figures described above, the bottom of an upper component, such as a wall, is shown, and the top of a lower component of the same type is shown (e.g., where the upper and lower walls meet at a corbel, etc.). Each component of that type can have the features shown and described for both the bottom and top of the component.

[0161] The manufactured wall, ceiling, and floor panels may be attached to the building frame, such as to separation walls, ceiling / floor panels, or interior or exterior structural framing. For example, a manufactured interior wall finish system and a manufactured ceiling finish system may be attached to one or more separation walls and / or floor panels within a building. Generally, any mechanism may be used to attach the wall, ceiling, and floor panels to the building. Any type of fastener may generally be used.

[0162] One or more components of the wall, ceiling, and floor panels described herein may be fabricated off-site in a factory or manufacturing facility and transported to a project site for installation in a building. The fabricated wall, ceiling, and floor panels and / or components thereof may be manufactured in various sizes. At the construction site, the wall, ceiling, and floor panels are attached to structural framing members, floor and ceiling panels, end walls, separation walls, utility panels, building utilities, or combinations thereof. The structural framing members, panels, or walls may provide support for the wall, ceiling, and floor panels.

[0163] The examples provided herein are for illustrative purposes only and should not be considered limiting of the scope of the present disclosure. Each exemplary embodiment may be practical for particular environments, such as urban mixed-use developments, low-rise residential units, and / or remote communities. The materials and dimensions of individual elements may be configured to comply with one or more of the following building codes: fire, energy, handicap, life safety, and acoustics (impact and ambient noise transmission) without departing from the scope of the subject matter of this disclosure. Elements and / or systems may also be configured to comply with social and / or religious codes, as desired. For example, materials, systems, methods, and / or apparatus may be configured to comply with the International Building Code as adopted in a jurisdiction. Furthermore, various components are referred to above as being "field panel installed," "field finish installed," and "factory installed" in some embodiments. In other embodiments, the installation location and / or installation method may differ from those referred to above. Furthermore, the various dimensions, gauges, and other specifications of the various components described above are for illustrative purposes only, and other embodiments may be implemented with components having different dimensions, gauges, specifications, etc.

[0164] The present disclosure is not limited in terms of the specific embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and embodiments can be made without departing from its spirit and scope. Functionally equivalent methods and apparatuses within the scope of the present disclosure, in addition to those recited herein, are possible from the foregoing description. Such modifications and embodiments are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. The present disclosure is not limited to a particular method, as there can, of course, be various methods. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0165] With respect to the use of virtually any plural and / or singular term herein, the term may be translated from plural to singular and / or from singular to plural as appropriate to the context and / or application. Various singular / plural permutations may be expressly set forth herein for clarity.

[0166] In general, the terms used in this specification, and particularly in the appended claims (e.g., the body of the appended claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "having at least," the term "include" should be interpreted as "including, but not limited to," etc.).

[0167] Where a specific number of introduced claim recitations is intended, such intention will be expressly stated in the claim; absent such recitation, no such intention exists. For example, to aid in understanding, the following appended claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as meaning that introducing a claim recitation with the indefinite article "a" or "an" limits a particular claim comprising such an introduced claim to embodiments comprising only one such recitation, even if the same claim also comprises the introductory phrase "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"). The same applies to the use of definite articles used to introduce claim recitations. Furthermore, even if a particular number of recitations in an introduced claim is explicitly recited, such recitation should be construed to mean at least the recited number (e.g., the bare recitation of "two recitations" without other modifiers means at least two recitations, or two or more recitations).

[0168] Furthermore, when a convention similar to "at least one of A, B, and C, etc." is used, generally such a structure is intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems with A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). When a convention similar to "at least one of A, B, or C, etc." is used, generally such a structure is intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" includes, but is not limited to, systems with A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Whether in the specification, claims, or drawings, virtually all separating words and / or phrases presenting two or more alternative terms should be understood to contemplate the possibility of comprising one term, either term, or both terms of the plurality. For example, the phrase "A or B" would be understood to include the possibilities of "A" or "B" or "A and B."

[0169] Furthermore, when features or aspects of the disclosure are described in terms of a Markush group, the disclosure is also thereby described in terms of any individual members or subgroups of members of the Markush group.

[0170] For all purposes, including providing a written description, all ranges disclosed herein encompass all possible subranges and subrange combinations. Any range described is fully descriptive and readily recognizable as being capable of being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. of the same range. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third, upper third, etc. All terms such as "up to," "at least," "greater than," "less than," etc., include the stated number and refer to ranges that can subsequently be broken down into subranges, as described above. Finally, ranges include individual members. For example, a group having 1 to 3 items refers to a group having 1, 2, or 3 items. Similarly, a group having 1 to 5 items refers to a group having 1, 2, 3, 4, or 5 items, etc.

[0171] The subject matter described herein may depict different components as being contained within or connected to different other components. Such depicted architectures are merely examples, and in fact, many other architectures that achieve the same functionality may be implemented. Conceptually, an arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Thus, for purposes of this specification, two components combined to achieve a particular function may be considered to be "associated" with each other such that the desired functionality is achieved, regardless of the architecture or medium between the components. Similarly, any two components so associated may also be considered to be "operably connected" or "operably coupled" to each other to achieve the desired functionality, and any two components capable of being associated in this manner may also be considered to be "operably coupled" to each other to achieve the desired functionality. Specific embodiments of operably coupleable include, but are not limited to, physically interlocking components and / or physically interacting components.

[0172] While various aspects and embodiments have been disclosed herein, other aspects and embodiments are possible. The various aspects and embodiments disclosed herein are illustrative and not intended to be limiting.

Claims

1. A heat insulating section; A first gypsum board layer provided on a first surface of the thermal insulation section; A second gypsum board layer installed on a second surface of the thermal insulation section opposite the first surface of the thermal insulation section; a plurality of first hat channels coupled to the first gypsum board layer; a plurality of second hat channels coupled to the second gypsum board layer; a first facing panel coupled to the plurality of first hat channels via a first trim piece; and a second finish panel coupled to the plurality of second hat channels via a second trim piece; A separation wall comprising: the first trim piece and the second trim piece comprise fiberglass reinforced plastic pultruded trim; each of the fiberglass reinforced plastic pultruded trims having an exterior portion and an interior portion; the interior portions capture edges of adjacent ones of the first and second finishing panels, and the interior portions snap into the corresponding ones of the first and second hat channels to attach the adjacent finishing panels to the corresponding hat channels; the exterior portions extend outwardly from the corresponding hat channels to permit removal of the adjacent finish panels by removing the fiberglass reinforced plastic pultruded trim without the use of tools. separation wall.

2. The separation wall further comprises: a first sheet metal member installed on an inner surface of the first gypsum board layer between the heat insulating portion and the first gypsum board layer; and a second sheet metal member attached to an inner surface of the second gypsum board layer between the heat insulating portion and the second gypsum board layer; The separation wall of claim 1 , comprising:

3. the first gypsum board layer comprises a glass fiber backed gypsum board; The second gypsum board layer comprises a glass fiber backed gypsum board. The separation wall according to claim 1 .

4. A modular building system, the modular building system comprising: The separation wall according to claim 1; Utility walls and the utility wall comprises: a utility wall insulation section; an insulation board installed on a first surface of the utility wall insulation section; a utility wall first gypsum board layer installed on the insulation board at a first side of the utility wall insulation; a second utility wall gypsum board layer installed on a second side of the utility wall insulation section opposite the first side of the utility wall insulation section; a weather-resistant barrier installed over the utility wall first gypsum board layer; and a vapor retarding layer disposed on the utility wall second gypsum board layer; Equipped with Modular building system.

5. The utility wall further comprises: one or more furring strips coupled to an exterior of the utility wall above the weather-resistant barrier; one or more exterior finish panels coupled to the one or more furring strips; 5. The modular building system of claim 4, comprising:

6. The utility wall further comprises: one or more hat channel members coupled to the utility wall second gypsum board layer; one or more trim pieces corresponding to the one or more hat channel members; and one or more interior finish panels coupled to the utility wall via the one or more trim pieces; 6. The modular building system of claim 5, comprising:

7. the utility wall insulation comprises multiple layers of insulation; 5. The modular building system of claim 4.

8. A modular building system, comprising: The separation wall according to claim 1; An end wall; and the end wall comprises: an end wall insulation portion; an end wall insulation layer installed on a first surface of the end wall insulation portion; An end wall first gypsum board layer installed on the surface of the end wall insulation layer opposite the end wall insulation portion; a weather-resistant barrier installed on a surface of the end wall first gypsum board layer opposite the end wall insulation layer; a second end wall gypsum board layer installed on a second surface opposite the first surface of the end wall insulation layer; and a vapor suppression layer disposed on the inner surface of the end wall second gypsum board layer between the end wall second gypsum board layer and the end wall insulation portion; A modular building system that includes:

9. The end wall further comprises: an end wall first sheet metal layer disposed on an inner surface of the end wall insulation layer between the end wall insulation layer and the insulation portion; and an end wall second metal sheet layer provided on the inner surface of the end wall second gypsum board layer between the end wall second gypsum board layer and the end wall insulation portion; 9. The modular building system of claim 8, comprising:

10. The end wall further comprises: one or more hat channel members coupled to the end wall second gypsum board layer; one or more interior finish panels coupled to the one or more hat channel members via corresponding trim pieces; and a thermal insulation material installed in a space defined by the end wall second gypsum board layer, the one or more hat channel members, and the one or more interior finish panels; 10. The modular building system of claim 9, comprising:

11. A modular building system, comprising: The separation wall according to claim 1; Corbel beams and The corbel beam comprises: A hollow structural beam; a wide flange beam disposed within the hollow structural beam; The corbel beam, The hollow structural beam is filled with grout so as to surround the wide flange beam disposed within the hollow structural beam. Modular building system.

12. the corbel beam further comprises a plate disposed within the hollow structural beam and adjacent to the flange of the wide flange beam within the hollow structural beam; 12. The modular building system of claim 11.

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