Structural modules for concrete building construction

Abstract

A containerized, transportable, pre-engineered, pre-fabricated, pre-assembled, adjustable, structural modular building system is disclosed, comprising a plurality of structural modules comprising a plurality of horizontal structural decks and vertical structural frames to be used in building construction. The building system is transportable world-wide using existing standardized ISO shipping methodologies of truck, train and shipping vessel. The structural modules may be expanded and contracted to vary the height, length, and width of the structural module based on building specifications. In such, the structural modules may be used for buildings having various floor dimensions, and may form self-contained structural elements within the building structure. In a single module configuration, the bottom horizontal structural deck is positioned between a first side deck and a second side deck. The first and second side decks are each rotationally engaged to each side of the bottom deck to form a building module. A track system slidingly engages with a plurality of structural frames and includes a locking mechanism to retain the plurality of structural frames in position along a length of the each of the bottom deck, the first side deck and the second side deck. A plurality of corrugations affixed to each of the bottom deck, the first side deck, and the second side deck to form a surface whereon concrete is poured.

1 . A containerized, transportable, structural modular building system, comprising:
 a plurality of pre-engineered, pre-assembled, and adjustable structural modules comprising a plurality of adjustable horizontal structural decks and adjustable vertical structural frames which, when positioned along an x-axis or a y-axis of a structure, resist moments about those axes;   a bottom deck of the plurality of horizontal structural decks positioned adjacent to a first side deck of the horizontal structural decks and a second side deck of the horizontal structural decks, the first and second side decks of the horizontal structural decks each rotationally engaged to each side of the bottom deck to form an adjustable structural module of the structural modular building system;   a track system slidingly engaged with a plurality of adjustable vertical structural frames and including a locking mechanism to retain the plurality of adjustable vertical structural frames in position along a length of the bottom deck;   a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck; and   wherein the plurality of corrugated decks are constructed and arranged to form a structural deck constructed and arranged to receive and support the wet load of concrete poured thereon without additional bracing.   
     
     
         2 . (canceled) 
     
     
         3 . The system of  claim 1 , wherein the plurality of corrugated decks are anchored to the horizontal deck steel members via a plurality of nelson studs, and wherein the corrugated decks are constructed and arranged to be filled with concrete to form a composite deck. 
     
     
         4 . The system of  claim 3 , further comprising a perimeter forming an anchor for the plurality of nelson studs. 
     
     
         5 . The system of  claim 4 , wherein the perimeter comprises a protrusion to permit the concrete to be poured at a sufficient thickness above the corrugation. 
     
     
         6 . The system of  claim 5 , wherein the plurality of adjustable vertical structural frames are positioned on opposing ends of the bottom deck, the first side deck, and the second side deck. 
     
     
         7 . The system of  claim 6 , wherein the plurality of adjustable vertical structural frames and horizontal structural decks are extendable in the x-direction, the y-direction, and the z-direction. 
     
     
         8 . The system of  claim 7 , wherein each adjustable vertical structural frame of the plurality of adjustable vertical structural frames comprises a top beam, a bottom beam, a left beam and a right beam, wherein each beam is extendable to increase the dimensions of the structural frame. 
     
     
         9 . A structural module system, comprising:
 a plurality of structural modules comprising a bottom deck positioned adjacent a first side deck and a second side deck, the first and second side decks rotationally engaged to each side of the bottom deck;   a track system to slidingly engage with a plurality of adjustable vertical structural frames, the track system including a locking mechanism to retain the plurality of adjustable vertical structural frames in position along a length of the each of the bottom deck, the first side deck and the second side deck; and   a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck, the plurality of corrugated decks arranged to form a surface; and   wherein the plurality of structural modules are stackable to permit the construction of a multilevel building, wherein the structural module system is pre-engineered and prefabricated prior to shipment.   
     
     
         10 . The system of  claim 9 , wherein the plurality of corrugated decks are anchored to the bottom deck, the first side deck, and the second side deck via a plurality of nelson studs. 
     
     
         11 . The system of  claim 10 , further comprising a perimeter forming an anchor for the plurality of nelson studs. 
     
     
         12 . The system of  claim 11 , wherein the perimeter comprises a protrusion to permit the concrete to be poured at a sufficient thickness above the corrugation. 
     
     
         13 . The system of  claim 12 , wherein the plurality of adjustable vertical structural frames are positioned on opposing ends of the bottom deck, the first side deck, and the second side deck. 
     
     
         14 . The system of  claim 13 , wherein each of the plurality of adjustable vertical structural frames are extendable in at least one of an x-direction, a y-direction, and a z-direction. 
     
     
         15 . The system of  claim 14 , wherein the bottom deck, the first deck, and the second deck are each extendable in at least one of an x-direction or a y-direction. 
     
     
         16 . The system of  claim 15 , further comprising at least one support beam releasably engaged with each of the bottom deck, the first side deck, and the second side deck to distribute the load of the concrete. 
     
     
         17 . The system of  claim 16 , wherein each adjustable vertical structural frame of the plurality of adjustable vertical structural frames comprise a top beam, a bottom beam, a left beam and a right beam, wherein each beam is extendable to increase the dimensions of the structural frame. 
     
     
         18 . (canceled) 
     
     
         19 . A structural module system, comprising:
 a plurality of expandable structural modules comprising a bottom deck positioned adjacent a first side deck and a second side deck, the first and second side decks rotationally engaged to each side of the bottom deck;   a track system to slidingly engage with a plurality of expandable structural frames, the track system including a locking mechanism to retain the plurality of expandable structural frames in position along a length of the each of the bottom deck, the first side deck and the second side deck; and   a plurality of corrugated decks affixed to each of the bottom deck, the first side deck, and the second side deck, the plurality of corrugated decks arranged to form a surface whereon concrete is poured,   wherein the plurality of expandable structural modules are configurable in a folded configuration to permit shipping and wherein the plurality of structural modules are stackable in an unfolded configuration to permit the construction of a multilevel building.   
     
     
         20 . The system of  claim 19 , wherein the plurality of corrugated decks are anchored to the bottom deck, the first side deck, and the second side deck via a plurality of nelson studs.