Rapidly deployable modular building and methods

Abstract

A modular building comprises a sled comprising a rectangular box frame. A shed comprising a steel framework of spaced apart columns that are linked to one another by overhead ceiling beams to provide a rigid structural frame. A sliding expansion modules is attached to the shed.

1 . A modular building comprising:
 (a) a sled comprising a rectangular box frame;   (b) a shed comprising a steel framework of spaced apart columns that are linked to one another by overhead ceiling beams to provide a rigid structural frame; and   (c) sliding expansion modules attached to the shed.   
   
   
       2 . The modular building of  claim 1  wherein the sled comprises a rectangular box frame composed of open web beams. 
   
   
       3 . The modular building of  claim 2  wherein the open web beams are oriented in a rectangular configuration to form a three-dimensional box. 
   
   
       4 . The modular building of  claim 2  wherein the sled comprises a plurality of sidewalls formed by vertical rectangle frames of beams. 
   
   
       5 . The modular building of  claim 1  wherein the sled further comprises an axle housing for receiving an axel for the attachment of wheels that allow the sled to be moved. 
   
   
       6 . The modular building of  claim 1  comprising floor joists extending across the upper surface of the sled. 
   
   
       7 . The modular building of  claim 1  wherein the sled comprises an under floor distribution of electrical and mechanical services. 
   
   
       8 . The modular building of  claim 1  wherein the sled comprises a rectangular box frame that includes a plurality of parallel and spaced apart wide flange beams. 
   
   
       9 . The modular building of  claim 8  wherein the beams comprise end portions that are located along the external perimeter of the sled and which have welded-on flat plates with bolt holes. 
   
   
       10 . The modular building of  claim 1  comprising an array of tubular joists are placed on top of the beams and spaced apart from one another to serve as floor joists. 
   
   
       11 . The modular building of  claim 1  wherein columns of the shed includes major and minor columns, the major columns having a larger cross-sectional area than the minor columns. 
   
   
       12 . The modular building of  claim 11  wherein the minor columns are spaced apart a sufficient distance to allow the space between the columns to be pre-sized to dimensions suitable to receive wall panels or doors. 
   
   
       13 . The modular building of  claim 12  wherein the wall panels are light impermeable or light permeable panes. 
   
   
       14 . The modular building of  claim 12  wherein the shed comprises long exterior sidewalls that are absent structural reinforcements. 
   
   
       15 . The modular building of  claim 1  wherein the shed comprises a ceiling that is an open area. 
   
   
       16 . The modular building of  claim 1  wherein the expansion module comprise a steel frame that is attached to an open sidewall or end wall of the shed to expand the usable enclosed space provided by the shed. 
   
   
       17 . The modular building of  claim 1  wherein the expansion module comprises major columns that form the corners of its structural frame with at least two of the columns being external to the shed, and the two other columns being integrated into a sidewall of the shed. 
   
   
       18 . The modular building of  claim 1  wherein the expansion module is sized smaller than the shed. 
   
   
       19 . A modular building comprising:
 (a) a sled;   (b) first and second expansion modules supported by the sled, each expansion module comprising a structural frame with an external sidewall, and the expansion modules being linked to one another by a plurality of ceiling beams to define an open interior space; and   (c) a clerestory roof mounted over the ceiling beams.   
   
   
       20 . The modular building of  claim 19  wherein the external sidewall of the expansion modules comprises major columns located at corners, and minor columns located between the major columns, the major columns having a larger cross-sectional area than the minor columns. 
   
   
       21 . The modular building of  claim 20  further comprising diagonal columns to increase lateral and shear strength. 
   
   
       22 . The modular building of  claim 20  wherein the major columns form corners of the structural frame, and at least two of the major columns are integrated into each external sidewall. 
   
   
       23 . The modular building of  claim 20  wherein the major and minor columns comprise tubes of structural steel which are linked together with tube steel headers and bolts. 
   
   
       24 . The modular building of  claim 20  wherein the minor columns are spaced apart a sufficient distance to allow the distance between the minor columns to be pre-sized to dimensions suitable to receive wall panels or doors. 
   
   
       25 . The modular building of  claim 25  wherein the wall panels are light impermeable panes. 
   
   
       26 . The modular building of  claim 25  wherein the wall panels are light permeable panes. 
   
   
       27 . The modular building of  claim 19  wherein the first and second expansion modules are supported by a sled, the sled comprising a rectangular box frame. 
   
   
       28 . The modular building of  claim 19  wherein the structural frame comprises a preassembled structure having completed welding, drilling and cutting. 
   
   
       29 . The modular building of  claim 19  further comprising a shed having a steel framework of spaced apart columns that is between the expansion modules. 
   
   
       30 . The modular building of  claim 19  wherein the expansion modules are rectangular structures. 
   
   
       31 . The modular building of  claim 19  wherein the clerestory roof is capable of receiving ceiling panes that include light permeable panes, light impermeable panes, or solar panels. 
   
   
       32 . The modular building of  claim 31  wherein the clerestory roof comprises onsite assembled trusses, custom aluminum extrusion rafters, and structural metal decking. 
   
   
       33 . The modular building of  claim 19  further comprising an external awning that serves as a sunshade, and is made from solar panels.