Modular building formed using a structural panel

Abstract

A structural panel includes perimeter rails and parallel joists having top and bottom surfaces lying in common parallel planes. Between the joists and the rails are diagonal planar bridge members extending obliquely in zigzag manner such that an end of one of the bridge members butts an opposed end of a next one of the bridge members at a side face of the joist. Planar top cover sheets bottom cover sheet are adhesively bonded to the top and bottom surfaces of the rail members, bridge members and joists. When used in a modular building, the floor has sufficient stiffness for the module to be transported from an assembly location in finished condition with all interior and exterior cladding attached and with the walls are topped by finished sandwich ceiling panels. The roof structure spanning the assembled modules is built on at the installation location.

1 . A modular building comprising:
 at least two separate modular base sections which are constructed so as to be separately transportable from a location of construction to a location of installation;   each modular base section including a floor structure and upstanding walls mounted on the floor structure;   the base sections being arranged to be connected so as to mate the walls to define a peripheral wall and interior walls of the modular building;   a roof to cover the peripheral wall with the modular base sections connected;   the floor structure of each modular base section having sufficient stiffness alone independently of the stiffness of the walls to provide stiffness for the modular base section to allow the modular base section to be transported and installed with the interior and peripheral wall finished and with the modular base section separate from the other modular base sections.   
   
   
       2 . The modular building according to  claim 1  wherein the interior walls and the peripheral wall are finished with all electrical connections and plumbing installed; the interior walls and the peripheral wall are finished with all windows, doors, and interior coverings installed; and the peripheral wall is finished with all exterior coverings installed. 
   
   
       3 . The modular building according to  claim 1  wherein the roof is a separate construction from the modular base sections. 
   
   
       4 . The modular building according to  claim 3  wherein the roof includes trusses spanning the peripheral wall so as to bridge over at least two of the modular base sections. 
   
   
       5 . The modular building according to  claim 3  wherein the roof is arranged so as to be constructed at the installation location after connection of the modular base sections. 
   
   
       6 . The modular building according to  claim 1  wherein each of the modular base sections includes ceiling panels covering an open top of the walls thereof such that the ceiling panels form a top cover during transportation of the modular base sections. 
   
   
       7 . The modular building according to  claim 6  wherein the ceiling panels are structural sandwich panels formed of top and bottom sheet material and a layer of foam therebetween and connected thereto. 
   
   
       8 . The modular building according to  claim 1  wherein each of the modular base sections has a width of 12 feet and a length of 40 feet. 
   
   
       9 . The modular building according to  claim 1  wherein there is provided a lifting assembly for lifting each modular base section comprising a plurality of mounting plates fastened to the floor structure at spaced positions thereon with each plate having a captive nut carried thereon and providing an end of the nut exposed at the top cover sheet, the lifting assembly including a plurality of threaded rods each for fastening to a respective nut so as to extend therefrom at right angles outwardly from the floor structure. 
   
   
       10 . The modular building according to  claim 9  wherein the lifting assembly includes a plurality of second mounting plates extending at right angles to the floor structure and fastened to the floor structure at spaced positions thereon with each second mounting plate having a captive nut carried thereon and providing an end of the nut exposed at the bottom of the floor structure for receiving a threaded fastener attached thereto. 
   
   
       11 . The modular building according to  claim 2  wherein the finished peripheral wall covering comprises stucco. 
   
   
       12 . The modular building according to  claim 2  wherein the finished interior wall covering comprises drywall. 
   
   
       13 . A modular building comprising:
 at least two separate modular base sections which are constructed so as to be separately transportable from a location of construction to a location of installation;   each modular base section including a floor structure and upstanding walls mounted on the floor structure;   the base sections being arranged to be connected so as to mate the walls to define a peripheral wall and interior walls of the modular building;   a roof to cover the peripheral wall with the modular base sections connected;   the interior walls and the peripheral wall being finished with all electrical connections and plumbing installed;   the interior walls and the peripheral wall being finished with all windows, doors, and coverings installed;   the peripheral wall being finished with all exterior covering installed;   the floor structure of each modular base section having sufficient stiffness to provide stiffness for the modular base section to allow the modular base section to be transported and installed with the interior and peripheral wall finished and with the modular base section separate from the other modular base sections.   
   
   
       14 . The modular building according to  claim 13  wherein the finished peripheral wall covering comprises stucco. 
   
   
       15 . The modular building according to  claim 13  wherein the finished interior wall covering comprises drywall. 
   
   
       16 . The modular building according to  claim 13  wherein the roof is a separate construction from the modular base sections constructed at the installation location after connection of the modular base sections and includes trusses spanning the peripheral wall so as to bridge over at least two of the modular base sections. 
   
   
       17 . A modular building comprising:
 at least two separate modular base sections which are constructed so as to be separately transportable from a location of construction to a location of installation;   each modular base section including a floor structure and upstanding walls mounted on the floor structure;   the base sections being arranged to be connected so as to mate the walls to define a peripheral wall and interior walls of the modular building;   the interior walls and the peripheral wall being finished with all electrical connections and plumbing installed;   the interior walls and the peripheral wall being finished with all windows, doors, and coverings installed;   the peripheral wall being finished with all exterior covering installed;   each modular base section having sufficient stiffness to allow the modular base section to be transported and installed with the interior and peripheral wall finished and with the modular base section separate from the other modular base sections;   wherein each of the modular base sections includes ceiling panels covering an open top of the walls thereof such that the ceiling panels form a top cover during transportation of the modular base sections;   and a roof to cover the peripheral wall with the modular base sections connected wherein the roof is a separate construction from the modular base sections constructed at the installation location after connection of the modular base sections and includes trusses spanning the peripheral wall so as to bridge over at least two of the modular base sections.   
   
   
       18 . The modular building according to  claim 17  wherein the ceiling panels are structural sandwich panels formed of top and bottom sheet material and a layer of foam therebetween and connected thereto.