Modular panelized building system and method

Abstract

A modular building frame panel may include first and second frame portions, each including first and second light gauge steel (LGS) vertical load-bearing members in a spaced substantially parallel relationship, top and bottom LGS edge purlins extending between upper and lower ends of the first and second LGS vertical load-bearing members, respectively, and configured to provide shear resistance of the upper and lower ends of the first and second LGS vertical load-bearing members, at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and, a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship.

1 . A modular building frame panel, comprising:
 a first frame portion, comprising:
 a first light gauge steel (LGS) vertical load-bearing member; 
 a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; 
 a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; 
 a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; 
 at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; 
   a second frame portion oriented one hundred and eighty degree (180°) about a vertical axis of the modular building panel relative to the first frame portion, comprising:
 a first light gauge steel (LGS) vertical load-bearing member; 
 a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; 
 a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; 
 a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; 
 at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and 
   a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship.   
     
     
         2 . The modular building frame panel of  claim 1 , wherein the first and second LGS vertical load-bearing members, the top LGS edge purlin, and the bottom LGS edge purlin have substantially identical cross-sectional shapes and sizes. 
     
     
         3 . The modular building frame panel of  claim 2 , wherein the cross-sectional shape of the first and second LGS vertical load-bearing members, the top LGS edge purlin, and the bottom LGS edge purlin are an open, substantially rectangular shape having an insertion opening defined on an elongated edge of the substantially rectangular shape. 
     
     
         4 . The modular building frame panel of  claim 3 , wherein the upper and lower ends of the first and second LGS vertical load-bearing members are received within insertion openings of the top and bottom LGS edge purlins, respectively. 
     
     
         5 . The modular building frame panel of  claim 1 , further comprising:
 a first portion of an intermediate purlin tensile connection assembly defined at a first end of the at least one LGS intermediate purlin; and   a second portion of an intermediate purlin tensile connection assembly defined at a second end of the at least one LGS intermediate purlin, wherein the first portion of the intermediate purlin tensile connection assembly is configured to connect in tension to a second portion of an intermediate purlin tensile connection assembly of an adjacent modular building panel.   
     
     
         6 . The modular building frame panel of  claim 5 , wherein the first and second portions of the intermediate purlin tensile connection assemblies are disposed on an interior of the at least one LGS intermediate purlin such that no portion of the first and second portions of the intermediate purlin tensile connection assemblies protrude from an exterior plane of the at least one LGS intermediate purlin, the exterior plane of the at least one LGS intermediate purlin substantially co-planar with an exterior plane of the top and bottom LGS edge purlins. 
     
     
         7 . The modular building frame panel of  claim 6 , wherein the first portion of the intermediate purlin tensile connection assembly comprises:
 a first intermediate purlin connection washer extending transversely across a width of the at least one LGS intermediate purlin, the first intermediate purlin connection washer received within slots defined in first and second opposing sides of the at least one LGS intermediate purlin; and   a bolt configured to extend transversely through the first intermediate purlin connection washer.   
     
     
         8 . The modular building frame panel of  claim 7 , wherein the second portion of the intermediate purlin tensile connection assembly comprises:
 a second intermediate purlin connection washer extending transversely across a width of the at least one LGS intermediate purlin, the second intermediate purlin connection washer received within slots defined in first and second opposing sides of the at least one LGS intermediate purlin, wherein the second intermediate purlin connection washer is configured to receive an end of the bolt; and   a nut configured to be secured on the end of the bolt after passing through second intermediate purlin connection washer.   
     
     
         9 . The modular building frame panel of  claim 8 , further comprising an opening defined in an exterior planar surface of the at least one LGS intermediate purlin providing access to the bolt and nut. 
     
     
         10 . The modular building frame panel of  claim 1 , wherein at least some of the plurality of cross-frame members define electrical conduits for the modular building panel. 
     
     
         11 . The modular building frame panel of  claim 1 , further comprising:
 a first portion of an edge purlin tensile connection assembly defined at a first end of the top LGS edge purlin and at a second end of the bottom LGS edge purlin; and   a second portion of an edge purlin tensile connection assembly defined at a second end of the top LGS edge purlin and at a first end of the bottom LGS edge purlin, wherein the first portion of the edge purlin tensile connection assembly is configured to connect in tension to a second portion of an edge purlin tensile connection assembly of an adjacent modular building panel.   
     
     
         12 . The modular building frame panel of  claim 11 , wherein the first and second portions of the edge purlin tensile connection assemblies are disposed on an interior of the top and bottom LGS edge purlins such that no portion of the first and second portions of the edge purlin tensile connection assemblies protrude from an exterior plane of the top and bottom LGS edge purlins, the exterior plane of the top and bottom LGS edge purlins substantially co-planar with an exterior plane of the at least one LGS intermediate purlin. 
     
     
         13 . The modular building frame panel of  claim 12 , wherein the first portion of the edge purlin tensile connection assembly includes a first edge purlin tensile connection washer assembly, and the second portion of the edge purlin tensile connection assembly includes a second edge purlin tensile connection washer assembly substantially identical to the first edge purlin tensile connection washer assembly,
 wherein the first edge purlin tensile connection washer assembly is configured to exert a force against a first LGS vertical load-bearing member when it is pulled into tension with a second edge purlin tensile connection washer assembly of an adjacent modular building panel, and   wherein the second edge purlin tensile connection washer assembly is configured to exert a force against a second LGS vertical load-bearing member when it is pulled into tension with a first edge purlin tensile connection washer assembly of an adjacent modular building panel.   
     
     
         14 . The modular building frame panel of  claim 13 , wherein the first edge purlin tensile connection washer assembly comprises:
 a first washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions;   a second, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive upper tabs of each of the first and second flanged portions of the first washer; and   a third, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive lower tabs of each of the first and second flanged portions of the first washer,   wherein the second planar portion of each of the second and third planar washers is configured to exert a force against an LGS vertical load-bearing member when the first washer is pulled into tension with a first washer of a second edge purlin tensile connection washer assembly of an adjacent modular building panel.   
     
     
         15 . The modular building frame panel of  claim 14 , further comprising a bolt configured to extend transversely through the first and second flanged portions of the first washer of the first edge purlin tensile connection washer assembly and a nut configured to be secured on the end of the bolt after passing through the first washer of the second edge purlin tensile connection washer assembly of an adjacent modular building panel. 
     
     
         16 . The modular building frame panel of  claim 15 , further comprising openings defined in an exterior planar surface of each of the top and bottom edge purlins providing access to the bolt and nut. 
     
     
         17 . The modular building frame panel of  claim 14 , wherein the second edge purlin tensile connection washer assembly comprises:
 a first washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions;   a second, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive upper tabs of each of the first and second flanged portions of the first washer; and   a third, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive lower tabs of each of the first and second flanged portions of the first washer,   wherein the second planar portion of each of the second and third planar washers is configured to exert a force against an LGS vertical load-bearing member when the first washer is pulled into tension with a first washer of a first edge purlin tensile connection washer assembly of an adjacent modular building panel.   
     
     
         18 . The modular building frame panel of  claim 14 , wherein the first edge purlin tensile connection washer assembly includes a fourth washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions, and wherein the fourth washer is configured to connect in tension to a fourth washer of a second edge purlin tensile connection washer of an adjacent modular building panel. 
     
     
         19 . The modular building frame panel of  claim 18 , further comprising a bolt configured to extend transversely through the first and second flanged portions of the fourth washer of the first edge purlin tensile connection washer assembly and a nut configured to be secured on the end of the bolt after passing through first and second flanged portions of the fourth washer of the second edge purlin tensile connection washer assembly of an adjacent modular building panel. 
     
     
         20 . The modular building frame panel of  claim 19 , wherein the fourth washer of the first edge purlin tensile connection washer assembly is disposed with an end of the first LGS vertical load-bearing member. 
     
     
         21 - 77 . (canceled)