Systems and methods of constructing, assembling, and moving modular washrooms

Abstract

Assembly time of a modular washroom may be reduced when compared to assembly of a conventional washroom, thereby reducing delays in occupancy of building units such as those in a strip mall. In one embodiment, a modular washroom comprises coupling devices on adjoining walls that are easily accessible so that the modular washroom may be more easily and quickly moveable than a conventional washroom. In one embodiment, the modular washroom comprises components that receive compliance certification prior to installation into a building structure, thereby reducing delays related to compliance inspections that typically occur after construction of a washroom at the building site.

1 . A modular washroom assembly for assembly within a framed building having a first height and sewer lines being formed within the foundation, the framed building also comprising a water source, the washroom assembly comprising: 
 a plurality of wall members each having an interior, an exterior side, a first lateral edge, a second lateral edge, and internal framing interposed between the interior and exterior sides such that the plurality of wall members have a thickness based at least in part on the internal framing wherein the plurality of wall members are of a second height that is less than the first height;    a plurality of fittings positioned within the wall members adapted to couple washroom fixtures mounted on the plurality of wall members to the water source and sewer lines;    a plurality of coupling members each having first and second legs that are interconnected with each other so that when two of the plurality of wall members are positioned such that the lateral edges are adjacent to each other with the wall members extending in substantially perpendicular directions to each other, the first and second leg of the coupling members respectively engage with the two adjacent wall members along the thickness dimension of the two adjacent wall members so as to retain the adjacent wall members in position with respect to each other; and    a plurality of cover members each having first and second legs, wherein the plurality of cover members are mounted on the exterior sides of the two adjacent wall members that are positioned adjacent to each other so as to define a generally right angle interconnection between the exterior sides of the wall members and at least partially hide from sight the plurality of coupling members.    
   
   
       2 . The modular washroom of  claim 1 , wherein the water source comprises an overhead water line provided at the framed building.  
   
   
       3 . The modular washroom of  claim 1 , wherein the modular washroom assembly receives code certification as a result of an inspection that is offsite to the framed building.  
   
   
       4 . The modular washroom of  claim 1 , wherein at least one of the wall members comprises gypsum board on the interior surface.  
   
   
       5 . The modular washroom of  claim 1 , wherein the plurality of wall members comprises four wall members arranged in a substantially rectangular configuration.  
   
   
       6 . The modular washroom of  claim 5 , wherein at least two of the walls are coupled with one or more bracket members positioned on inner surface of the at least two walls.  
   
   
       7 . The modular washroom of  claim 6 , wherein a junction between the at least two walls is located in a corner of the framed building such that the outside surface of the walls at the junction is not accessible.  
   
   
       8 . A modular washroom kit comprising: 
 a plurality of walls configured for assembly at a strip mall, the plurality of walls comprising at least 
 a first wall comprising an attachment mechanism for coupling a sink to the first wall, the first wall further comprising plumbing within the first wall configured for coupling to a water source at the strip mall; and  
 a second wall comprising electrical wires within the second wall and an electrical outlet on the second wall; and  
   a plurality of substantially L-shaped brackets for attaching pairs of walls together at the strip mall;    wherein an ICC-ES inspection certification for the modular washroom kit is issued prior to shipment of the kit to the strip mall for assembly.    
   
   
       9 . The modular washroom kit of  claim 8 , wherein the at least one wall is the first wall.  
   
   
       10 . The modular washroom kit of  claim 8 , wherein the at least one wall is the second wall.  
   
   
       11 . The modular washroom kit of  claim 8 , further comprising a plurality of ornamental covers configured for attachment to pairs of adjoining walls such that the L-shaped brackets are not visible.  
   
   
       12 . The modular washroom kit of  claim 8 , wherein the ICC-ES inspection certification is issued in response to a self-inspection by the fabricator of the modular washroom kit, wherein the self-inspection is according to the inspection criteria provided by ICC-ES.  
   
   
       13 . A method of assembling a modular washroom, the modular washroom comprising a plurality of walls and at least one of the walls comprises a fixture attached to the wall, the method comprising: 
 placing at least two walls of the modular restroom in a desired location within a building structure, the at least two walls having supports coupled near an upper end of the walls for supporting a ceiling;    positioning the ceiling on at least a portion of the supports; and    moving the ceiling so that the ceiling is supported by the supports.    
   
   
       14 . The method of  claim 13 , further comprising: 
 attaching a substantially L-shaped bracket on a first end of a first wall and a second end, and tightening a first screw through a first side of the bracket and the first end of the first wall; and tightening a second screw through a second side of the bracket into the second end of the second wall.    
   
   
       15 . The method of  claim 13 , wherein the building structure is selected from the group comprising: shopping centers, community centers, power centers, enclosed malls, tilt-up construction, strip malls, temporary “tent” facilities, gas stations, and convenience stores.  
   
   
       16 . A method of constructing components of a modular washroom, the method comprising: 
 (a) constructing at a manufacturing facility a plurality of walls of a modular washroom, wherein at least one of the walls comprises HVAC components within the wall and at least one of the walls comprises a fixture attached to the wall, the walls being configured for assembly at a building location remote to the manufacturing facility;    (b) presenting the constructed walls to an inspector at the manufacturing facility;    (c) obtaining an inspection certification for the constructed walls from the inspector after inspection of the constructed walls at the manufacturing facility; and    (d) combining the constructed walls into a kit for sale to a customer, wherein the kit comprises the plurality of walls and coupling devices for securing the plurality of walls in order to form a modular washroom.    
   
   
       17 . The method of  claim 16 , wherein the inspection certification is from ICC-ES.  
   
   
       18 . The method of  claim 16 , wherein at least one of the walls comprises one or more fixtures that are attached to the wall prior to the step of presenting.  
   
   
       19 . The method of  claim 16 , wherein at least one of the walls comprises plumbing and/or electrical components within the wall.  
   
   
       20 . A method of coupling adjacent walls of a modular washroom, the method comprising: 
 positioning a first substantially rectangular wall comprising a front surface and a rear surface separated by a first thickness, the first wall further comprising a left side and right side each between the front and rear surface and having widths equal to the first thickness;    positioning a second substantially rectangular wall comprising a second front surface and a second rear surface separated by a second thickness, the second wall further comprising a second left side and a second right side each between the second front and rear surfaces and having widths equal to the second thickness, the second wall being positioned so that the second right side contacts the left side of the first wall so that the first and second walls are substantially perpendicular to one another and so that the second right side and the left side are at least partially exposed; and    coupling at least one bracket to the exposed portions of the second right side and the left side so that the first and second walls are attached.    
   
   
       21 . The method of  claim 20 , wherein the bracket is substantially L-shaped.  
   
   
       22 . The method of  claim 20 , further comprising: 
 coupling a cover member to each of the first and second walls so as to substantially hide the bracket from view.