MODULAR ASSEMBLY BELOW GROUND LEVEL

Abstract

A modular assembly (20) is provided, comprising a modular frame (28) to be installed at least partially below ground level and at least two panels (34) attached to the modular frame (28), wherein the at least two panels (34) are made of a material that resists lateral, vertical, and shear forces generated by the surrounding materials below ground level. The modular frame (28) and the at least two panels (34) are joined as a unit prior to installation.

Description

MODULAR ASSEMBLY BELOW GROUND LEVEL FIELD OF INVENTION The present invention relates in general to modular construction techniques for the construction of multi-story residences and, more specifically, to a modular assembly for the construction of buildings below ground level. BACKGROUND OF THE INVENTION Residential and commercial buildings need foundations to support the considerable weight of building materials, provide a flat and level base for construction, and separate wood-based materials from contact with the ground, which could cause them to rot and become infested with termites. Foundations are commonly constructed with concrete. First, a pit corresponding to the size of the foundation is dug in the ground to the desired depth, based on the size and height of the area of ​​the building below ground level, such as a basement or mezzanine. Once the soil is removed, internal and external formwork made of wood or steel is erected along the perimeter of the building and spaced according to the designated thickness of the foundation walls. After the concrete is poured into the space between the formwork, i RQbnn / ι znz / R / YiAi Ref. 317667 Internal and external formwork and curing: the internal and external formwork is removed to expose the foundations. Additional formwork is then erected on the foundations to form the walls of the area below ground level. Installing the formwork, pouring the concrete, allowing the concrete to cure, and then removing the formwork takes several days and sometimes weeks. This adds significant time to the overall construction schedule for residential and commercial buildings, as well as increasing construction costs. It is a growing trend to construct multi-story residential buildings using modular units, especially in densely populated urban areas where heavy construction equipment has difficulty maneuvering. Modular construction reduces material waste, and because the units are assembled remotely, labor costs and working conditions are more closely controlled. These modules are built and assembled remotely, transported to the construction site, and then lifted into position by a crane. Many modules are up to 75 feet long and are assembled by stacking them vertically, side by side and end to end, allowing for a variety of configurations of the final building design.However, these modules are generally made of lightweight materials that are usually not structurally strong enough for the vertical, lateral, and shear forces applied to the foundations and walls below ground level by the surrounding soil and the weight of the building materials used to construct the floor or floors built above the area below ground level. Therefore, there is a need for a modular assembly for structures below ground level in residential and commercial buildings. BRIEF DESCRIPTION OF THE INVENTION The aforementioned need is met or exceeded by this modular assembly, which is designed for installation below ground level to support one or more floors of a residential or commercial building. To save time and costs, the modular assembly is manufactured at a remote location and transported to a construction site for quick and easy installation in an open area below ground level. In one embodiment, a modular assembly is provided that includes a modular frame to be installed at least partially below ground level and at least two panels attached to the modular frame, wherein the at least two panels are made of a material that resists the lateral, vertical, and shear forces generated by the I RQbnn / l 7P7 / E / YILI surrounding materials below ground level. The modular frame and at least two panels are joined as a unit before installation. In another embodiment, a modular system is provided for installation below ground level and is configured to support a multi-story building. The system includes at least two modular assemblies joined together as a unit, where each modular assembly is configured to be installed at least partially below ground level. Each modular assembly includes a modular frame and at least two panels attached to the modular frame, where the at least two panels are made of a material configured to resist the lateral, vertical, and shear forces generated by the surrounding materials below ground level, and where the modular frame and at least two panels are joined together as a unit prior to installation. In an additional embodiment, a method is provided for forming a modular assembly for below-ground installation configured to support a building, wherein the method includes attaching at least two panels to a modular frame at a remote location. The at least two panels are made of a material that resists lateral, vertical, and shear forces generated by the surrounding materials below ground level. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a schematic view of the present modular assembly being transported to a pit in the ground for a building; Figure 2 is a schematic view of the present modular assembly inserted in the well of Figure 1; Figure 3 is a schematic view of a residential building constructed on the modular assembly of Figure 2; Figure 4 is a fragmented and enlarged perspective view of a wall of the present modular assembly in a foundation wall; Figure 5 is an exploded perspective view of the modular assembly of Figure 1 showing a modular frame and a panel; Figure 6 is a perspective view of another modality of the present modular assembly where one side of the modular assembly is open; Figure 7 is a perspective view of another modality of the present modular assembly where two sides of the modular assembly are open; Figure 8 is another modality of the present modular assembly that includes finished interior walls; and Figure 9 is an additional modality of the present I RQbnn / l 7Π7 / Β / YΙΛΙ modular assembly showing multiple modular assemblies placed adjacent to each other. DETAILED DESCRIPTION OF THE INVENTION With reference to Figures 1-4, the present Modular Assembly 20 is designed for installation below ground level 22 for structural walls in areas below ground or subgrade level, such as basements, mezzanines, or cellars, of residential and commercial buildings. As shown in Figure 1, the Modular Assembly 20 is fabricated at a remote location and then transported as a modular unit to a construction site. Typically, as described above, the foundations and structural walls of a building are formed with poured concrete, which is time-consuming due to the installation and removal of formwork and additional time to allow the concrete to cure and harden. The present Modular Assembly 20 significantly reduces preparation and installation time because the structural walls are prefabricated and assembled as a modular unit at a remote location.When the modular assembly 20 arrives at a construction site, it is placed in a pit or area 24 excavated for a building as shown in Figures 1 and 2. The modular assembly 20 can be located or placed on foundations 26 as shown in Figure 3 or on gravel or other subsoil depending on the type of building being constructed. i RQbnn / ι ζηζ / κ / γίΛΐ With respect to Figures 4-5, the modular assembly 20 includes a modular frame 28 made of primary structural supports 30 and secondary structural supports 32. The primary structural supports 30 are connected to each other by suitable fasteners to form the external structure of the modular frame 28. In the illustrated embodiment, the primary structural supports 30 are made of iron, but they may be made of another metal, wood, or any suitable material. Furthermore, the primary structural supports 30 are preferably two-inch by twelve-inch supports of a designated length, but they may have any suitable thickness, dimension, and length. In Figure 5, the external structure is made with individual primary structural supports 30.Alternatively, two or more of the primary structural supports 30 can be connected together at the top, bottom or sides of the external structure to improve the strength and rigidity of the modular frame 28. After assembling the external structure of the modular frame 28, a plurality of secondary structural supports 32, i.e., studs, are joined between the upper and lower ends of the modular frame 28 to form the walls of the modular assembly 20. The secondary structural supports 32 are preferably two inches by eight inches and of a desired length, but may have any suitable thickness, dimension, and length. Furthermore, the secondary structural supports 32 are made of cold-formed steel, but may be made of wood or any other suitable material. In one embodiment, the secondary structural supports 32 may be joined between the walls at the upper end, the lower end, or both the upper and lower ends of the external structure as structural support for installing a floor, a roof, or both a floor and a roof over the modular assembly 20. When the construction of the modular frame 28 is complete, a plurality of subgrade panels 34 (Figure 5) are attached to the external surface 33 (Figure 4) of the modular frame 28. It should be noted that one or more of the panels 34 may be attached to the modular frame 28. Preferably, at least two of the panels 34 are attached to the modular frame 28 to form a desired modular assembly 20. In the illustrated embodiment, each of the panels 34 is attached to the modular frame 28 by means of suitable fasteners, such as screws, which are driven through the external surface of the panels and into the primary and / or secondary structural supports 30, 32 of the modular frame 28 to secure the panels to the modular frame. Alternatively, fasteners can be inserted through the primary and secondary structural supports 30, 32 and then into the inner surfaces of the panels 34 to fix the panels to the modular i RQbnn / ι znz / R / YiAi frame 28. In the illustrated embodiment, the 34 subgrade panels are made of a fiberglass-reinforced cementitious material that is rot-resistant, termite-resistant, mildew-resistant, and moisture-resistant (moisture content change of less than 10%). Furthermore, the material used to form the 34 panels is stable—that is, the panel will not sag or warp like conventional wood sheathing—non-combustible, dimensionally stable, and strong enough to support fill loads of 2,000 pounds per square foot and above, and to carry gravity and shear loads. Preferably, each 34 panel is configured to support a uniform load of up to 2,083 pounds per square foot when the secondary structural supports 32 are spaced at 12 inches and the shear wall design ratings are up to 1,726 pounds per linear foot.In the illustrated configuration, each 34-panel is 4 feet wide and 8 feet long with a thickness of 3 / 4 inch (0.75 inches). The 34-panel can also be 5 / 8 inch (0.625 inches) thick. It should be noted that the 34-panel can be any width, length, and thickness suitable for the desired construction specifications. Furthermore, each 34-panel weighs 5 pounds per square foot, which is significantly less than the weight of the concrete walls used for conventional below-grade areas in residential and commercial buildings. The lighter weight of the 34-panel also makes transporting and installing the modular assemblies easier and less expensive. In one modality, the physical and mechanical properties of subgrade panels 34 are described in the following table: i RQbnn / ι ζηζ / κ / γίΛΐ TEST STANDARD (ASTM NO.) CONCRETE FOUNDATION WALL VALUES CONCRETE FOUNDATION WALL XD VALUES Fastener Lateral Strength1 D1761 DRY >210 lb [0.93 kN] WET > 160 lb [0.71 kN] DRY >210 lb [0.93 kN] WET > 160 lb [0.71 kN] Density: Oven Dry2 C1185 75 lb / ft3 [1200 kg / m3] 75 lb / ft3 [1200 kg / m3] Weight: 3 / 4 inch Thickness Supplied D1037 5.3 lb / ft3 [25.9 kg / m2] 5.3 lb / ft3 [25.9 kg / m2] pH Value D1293 10.5 10.5 Coating variation with change in humidity (25-90% relative humidity) C1185 <0.10% <0.10% Thickness swelling D1037 Max. 3.0% Max. 3.0% Freeze / thaw resistance C1185 Passed 50 cycles Passed 50 cycles Mold resistance D3273 / G21 10 / 0 10 / 0 Water absorption3 C1185 <15.0% <15.0% Non-combustibility E136 Approved Approved Surface combustion characteristics E84 0 flame spread smoke development index 0 0 flame spread smoke development index 0 Long-term durability C1185 Min. 75% retention of physical properties 100% retention of physical properties Durability in water C1185 Min. 70% retention of physical properties 91% retention of physical properties Water vapor transmission (Method B) E96 Permeance <2 perm Permeance <2 perm. Notes: 1. Lateral fastener strength measured with applicable fasteners 2. Density measured in equilibrium conditioning according to section 5.2.3.1: evaluated 28 days after manufacture 3. Absorption measured from equilibrium conditioning followed by immersion in water for 48 hours Additionally, in applications where plywood is typically used on the exterior or interior of a wall, floor, or ceiling, Subgrade 34 panels may be used instead of plywood in accordance with ANSI PWF Specification and CAN CSA S406 Specification. As shown in Figure 4, the modular assembly 20 is placed on foundations 26, which may be one or more foundation walls or supports, where the entire assembly is at least partially below ground level to form a subgrade area, such as a basement, of a residential or commercial building. In this embodiment, a waterproof membrane or waterproof coating 36 is applied to the exterior surfaces of the modular assembly 20 to prevent moisture and water from penetrating the panels 34 and the joints between the panels, and entering the interior space of the modular assembly. Furthermore, as described below, the interior of the walls of the modular assembly 20 may be finished with insulation 35 placed in the spaces formed between the primary and secondary structural supports, and / or interior panels, such as boards, bonded to the inner surfaces of the primary and secondary structural supports.In another modality, the insulation 35 is placed on the outer or external surface of the modular assembly between the waterproof membrane / covering 36 and the surrounding fill soil. i RQbnn / ι ζηζ / κ / γίΛΐ With respect to Figures 5-7, each modular assembly 20 preferably includes at least four walls 38 made with the primary and secondary structural supports 30, 32 as described above. A plurality of panels 34 are joined to the modular assembly 20 to form a modular structure having solid external walls. The modular assembly 20 shown in Figure 5 is rectangular, but it is envisaged that the modular assembly may have any suitable shape or combination of shapes. Figures 6 and 7 show different embodiments of the modular assembly. For example, Figure 6 shows a modular assembly 40 having one open side 42, meaning there are no panels or secondary structural supports attached to this side of the modular assembly. This modular assembly 40 may be located adjacent to or connected to another modular assembly to form a large subgrade area.It should be noted that two or more of the modular assemblies can be placed adjacent to each other and / or connected to form a larger modular assembly. In another alternative configuration shown in Figure 7, modular assembly 44 has two open sides 46. It should be noted that one or more of the sides of the modular assembly can be open sides and / or part of the walls of the modular assembly can have openings, such as windows, doors, or stairwells. Typically, openings and holes are formed in structural walls below ground level or subgrade to allow water pipes, electrical conduits, or other structures to run through the walls. In conventional concrete walls, such openings and holes must be cut after the concrete has cured. Cutting concrete walls requires a concrete knife and / or drill bit and generates a significant amount of dust, which is hazardous to the person cutting the walls.The panels of this modular assembly 20 are designed to withstand the vertical, lateral, and shear loads of the surrounding soil materials used as fill, such as earth, rock, and gravel, and the construction above ground level, while still allowing the use of conventional blades and drill bits, such as carbide-tipped blades and drill bits, to cut openings and holes in the panels. In this way, the panels of the modular assembly 20 below ground level are much easier to cut and generate significantly less dust. With reference to Figure 8, in another embodiment, the modular assembly 48 includes a modular frame 50 and a plurality of panels 52 fixed to the modular frame as described above. In this embodiment, the modular assembly 48 also includes finished interior walls 54 that have a plurality of boards 56 fixed to the modular frame 50 adjacent to the inner surfaces of the panels 52. The finished interior walls 54 may also include tiles, carpet, or any suitable combination of finishing materials. In the illustrated embodiment, the joints of the boards 56 are taped, filled with joint compound, and coated with at least one primer. It should be noted that the inner surfaces of the boards 56 may also be painted so that the modular assembly 48 is fully finished when installed on a foundation or other underlying surface. With reference to Figure 9, in an additional embodiment, two or more modular assemblies 58, i.e., modular assemblies 58a, 58b, and 58c, are fixed together as a single unit. In this embodiment, the three modular assemblies 58a, 58b, and 58c are located adjacent to each other and / or fixed together. As shown in Figure 9, the modular assemblies 58a, 58b, and 58c may be of different sizes, i.e., have different dimensions and shapes, as illustrated, or one or more of the modular assemblies may have the same dimensions and shapes. Furthermore, the modular assemblies 58a, 58b, and 58c may be fixed together at a remote location and transported to a construction site, or the modular assemblies may be transported individually and fixed at the construction site. In addition, one or more of the modular assemblies 58a, 58b, and 58c may have one or more open sides or openings, and / or an interior wall finished as described above.It should be noted that the 60 subgrade panels are preferably four feet by eight feet and have a thickness of 5 / 8 inch (0.625) to 1 inch, but can be any suitable dimensions and thickness. Furthermore, the 60 panels can be positioned vertically or horizontally on the modular frame, just like the 60a and 60b panels, and can be cut to any suitable size or shape needed to cover the exterior of the modular frame. Although particular modalities of the present modular assembly have been described herein, people of intermediate skill will appreciate that changes and modifications can be made to it without departing from the invention in its broader aspects and as set forth in the following claims. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

Having described the invention as above, the following claims are claimed as property:

1. A modular assembly below ground level, characterized in that it comprises: a modular frame to be installed at least partially below ground level; and at least two panels attached to the modular frame, wherein the at least two panels are made of a material that resists lateral, vertical and shear forces generated by the surrounding materials below ground level, wherein the modular frame and the at least two panels are joined as a unit prior to installation.

2. The modular assembly according to claim 1, characterized in that the at least two panels are made of a cementitious material reinforced with fiberglass.

3. The modular assembly according to claim 1, characterized in that the modular frame includes a plurality of primary structural supports and a plurality of secondary structural supports joined between the upper and lower ends of the primary structural supports 17.

4. The modular assembly according to claim 3, characterized in that at least one of the plurality of primary structural supports is made of iron or wood.

5. The modular assembly according to claim 3, characterized in that at least one of the plurality of secondary structural supports is made of steel or wood.

6. The modular assembly according to claim 1, characterized in that it further comprises a finished wall installed on an interior surface of the modular frame.

7. The modular assembly according to claim 6, characterized in that the finished wall includes boards.

8. The modular assembly according to claim 1, characterized in that it further comprises a waterproof coating or waterproof membrane applied to an outer surface of the modular frame.

9. The modular assembly according to claim 1, characterized in that the modular frame includes at least one open side.

10. A modular system for installation below ground level and configured to support a multi-story building I RQbnn / l 7A7 / E / YILI, characterized in that it comprises at least two modular assemblies according to claim 1 that are fixed together as a unit, wherein each of the modular assemblies is configured to be installed at least partially below ground level.

Images