Pre-fabricated building modules and method of installation

Abstract

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

1 . A stackable prefabricated building module for forming one or more rooms of a multi-story building located at a first location and configured for stacking with other stackable prefabricated building modules, said module comprising: 
 a floor frame for supporting a floor assembly;    a ceiling frame for supporting a ceiling assembly, wherein stacking of said module with one of said other modules forms a ceiling cavity between a ceiling assembly of said module and the floor assembly of said other module, said ceiling cavity providing space for housing ventilation ducting and utility equipment therewithin;    a plurality of columns extending vertically from below said floor frame to above said ceiling frame, one of said columns located at each corner of said module, each of said columns extending below said floor assembly for providing a leg for connecting to an adjacent level of said building beneath said module, wherein said columns support the weight of a predetermined number of stacked modules as a function of the size and number of said columns;    a plurality of floor edge connectors, each of said floor edge connectors for coupling said floor assembly to an adjacent portion of the same floor level of said building; and    a plurality of column connectors, each of said column connectors installed at the top of a corresponding column for connection to a leg of one of said other modules positioned adjacent to and above said module.    
   
   
       2 . The module of  claim 1 , further comprising a vertical shaft section for providing ventilation and for enclosing a vertical section of a plurality of risers used for coupling utilities to each said module, said shaft section including a seal to seal said shaft section to the shaft sections of any adjoining building modules above and below said module.  
   
   
       3 . The module of  claim 1 , further comprising a plurality of metal stud insert panels for framing perimeter wall spaces between said columns.  
   
   
       4 . The module of  claim 1 , further comprising a plurality of beams coupling said columns to said ceiling frame and floor frame.  
   
   
       5 . The module of  claim 1 , wherein said module is comprised of tubular light gauge steel members.  
   
   
       6 . The module of  claim 1 , wherein said adjacent portion is comprised of wood.  
   
   
       7 . The module of  claim 1 , wherein said adjacent portion is comprised of steel.  
   
   
       8 . The module of  claim 1 , wherein each of said column connectors includes one or more plates welded at the top of each column and having one or more holes therein, said module further comprising one or more high strength bolts, each said bolt for fastening the plates of each said column to the adjacent leg of another said module positioned adjacent to and above said module.  
   
   
       9 . The module of  claim 8 , wherein said holes further provide lifting points during installation of said module at said first location.  
   
   
       10 . The module of  claim 8 , wherein each said plate enables the further coupling of said each said column via welding to the adjacent leg of another said module positioned adjacent to and above said module.  
   
   
       11 . The module of  claim 1 , wherein said column connector comprises one or more plates welded at the top of each column, each said plate for enabling the coupling of said each said column via welding to the adjacent leg of another said module positioned adjacent to and above said module.  
   
   
       12 . The module of  claim 1 , further comprising an air conditioning unit located in said ceiling cavity and a ceiling access panel for enabling access to said air conditioning unit.  
   
   
       13 . The module of  claim 1 , further comprising a plurality of casters disposed to said legs for facilitating movement of said module during fabrication.  
   
   
       14 . The module of  claim 1 , wherein said floor assembly includes a concrete topping disposed on a steel deck supported by steel joists.  
   
   
       15 . The module of  claim 14 , wherein a coiled steel bar insert is embedded into said concrete topping for enabling attachment of threaded steel bar dowels at the perimeter of said floor assembly of said module, to enable said concrete floor topping to be structurally connected to the concrete structural floor of an adjacent level of said building so as to provide further resistance to lateral loads.  
   
   
       16 . The module of  claim 1 , wherein said module is the lowest module of said stack and for installation on the lowest floor of said building, said module forming a foundation cavity for accommodating said floor assembly and its attachment to a foundation of said building, the legs of said module sized to be welded to a base steel plate anchored into a base foundation of said building when said module is installed at said first location.  
   
   
       17 . The module of  claim 1 , further comprising bent steel plate hangers welded to said floor frame of said module for providing support for an adjacent floor assembly.  
   
   
       18 . The module of  claim 1 , further comprising a threaded bar coupled to an end of said leg to enable leveling with adjacent levels.  
   
   
       19 . The module of  claim 1 , wherein perimeter walls are formed on said module, said perimeter walls having an exterior surface and a cladding thereon.  
   
   
       20 . The module of  claim 15 , further comprising diagonal steel bracing member positioned between said columns at said perimeter walls for providing increased resistance to lateral loads.  
   
   
       21 . The module of  claim 16 , wherein said diagonal steel bracing is about the same thickness as said columns such that said bracing is concealed and fire-protected by said perimeter wall cladding.  
   
   
       22 . The module of  claim 1 , wherein said module is fabricated at a second location and is adapted to be handled and transported on a vehicle on a public road for transporting said module from said second location to said first location.  
   
   
       23 . The module of  claim 2 , wherein each shaft section includes an access door for enabling connection to said risers and a grating to enable air flow.  
   
   
       24 . The module of  claim 1 , wherein said building is a preexisting building having one or more other stacked modules and said module is installed at said first location by stacking said module with said other stacked modules in said building, said module providing a predetermined amount of support for loads of the surrounding structure of said building.  
   
   
       25 . The module of  claim 1 , wherein said module is inserted from a top of said building and does not support for the loads of the surrounding structure of said building.  
   
   
       26 . A prefabricated building module for forming one or more rooms of a building located at a first location and configured to be slidable into an opening of said building for installation, said module comprising: 
 a floor frame for supporting a floor assembly;    a ceiling frame for supporting a ceiling assembly;    a plurality of columns extending vertically from below said floor frame to above said ceiling frame, one of said columns located at each corner of said module;    a plurality of floor edge connectors, each of said floor edge connectors for coupling said floor assembly to an adjacent portion of the same floor level of said building; and    a plurality of column connectors, each of said column connectors installed at the top of a corresponding column;    wherein said module enables connection to the risers of said building used for coupling utilities to each said module.    
   
   
       27 . The module of  claim 26 , wherein said module is attached to said building via a plurality of steel angles.  
   
   
       28 . A method for storage and transport of a prefabricated building module, said module to be installed in a building at a first location comprising the steps of: 
 providing at least one upper connecting steel plate for lifting said module during fabrication at a second location;    attaching wood members to each said plate;    installing a temporary roof cover supported by said wood members;    installing tubular steel legs extending from the bottom of said module at each corner;    attaching wood sleepers via threaded rods at the bottom of said tubular steel legs so that said module is suitable for transportation; and    after fabrication, with said temporary roof cover in place, wrapping said module with a tear-resistance waterproof protective membrane secured by wood strips at the bottom of the module.    
   
   
       29 . The method of  claim 28 , further comprising the steps of removing said membrane, said wood strips, and said temporary roof cover before installation of said module in said building; and 
 removing said wood sleepers once said module is lifted by a crane for permanent installation in said building.    
   
   
       30 . The method of  claim 28 , further comprising the step of attaching a plurality of casters to said tubular steel legs to facilitate movement of said module during fabrication, said casters being removed prior to transport of said module.  
   
   
       31 . The method of  claim 28 , wherein said legs and said at least one upper connecting steel plate are attached to said module at said first location.  
   
   
       32 . A method of installation of a prefabricated building module into a building at a first location comprising the steps of: 
 fabricating said module at a second location a distance away from said first location; transporting said module to said first location;    sliding said building module into an opening of said building; and    coupling said module to a plurality of risers housed within a shaft of said building for connecting said module to utilities and ventilation systems therein.    
   
   
       33 . A method of installation of a prefabricated stackable building module into a building at a first location, said module having a vertical shaft section for providing ventilation and for enclosing a vertical section of a plurality of risers, comprising the steps of: 
 fabricating said module at a second location a distance away from said first location;    transporting said module to said first location;    inserting said module from a top of said building into a cavity in said building via a crane; and    operatively connecting said shaft section to a shaft section of one or more adjacent stackable modules; each said shaft section including a seal such that said shaft sections of adjoining building modules are automatically sealed during installation of said module.    
   
   
       34 . The method of  claim 33 , wherein said inserting step comprises stacking said module onto a stack of one or more other prefabricated stackable building modules via a crane; said module providing a predetermined amount of support for loads of the surrounding structure of said building, and further comprising the step of connecting said module to said building such that said module provides a predetermined amount of support for loads in the surrounding structure of said building.  
   
   
       35 . The module of  claim 1 , further comprising panelized interior cladding for built-in room items enabling sub-assembly fabrication thereof.