Module for use in preparing a prefabricated structure, method for manufacturing same and transport frame

Abstract

The present invention provides a reinforced concrete module for use in preparing a prefabricated structure comprising a horizontal slab, four corner columns, perimeter beams extending downwardly from a respective longitudinal and transversal edges of the horizontal slab and extending between and connected to adjacent columns; at least two transverse ribs located on an underside of the horizontal slab and extending between two opposing perimeter beams, wherein the module is fabricated as a unitary body. Also provided is a method for fabricating the module, as well as a transport frame configured to support a module on a transport vehicle.

We claim: 
     
         1 . A reinforced concrete module for use in preparing a prefabricated structure, the module comprising:
 a horizontal slab defining two opposing longitudinal edges, two opposing transversal edges, and four corners;   four corner columns, each said corner column being located at a respective corner; and   two longitudinal perimeter beams, each of said longitudinal perimeter beams extending downwardly from a respective longitudinal edges of the horizontal slab and extending between and connected to adjacent columns;   two transversal perimeter beams, each of said transversal perimeter beams extending downwardly from the transversal edges of the horizontal slab and extending between and connected to adjacent columns;   at least two transverse ribs located on an underside of the horizontal slab and extending between opposing longitudinal perimeter beams; and   an attachment element located at the base of each said corner column,   configured for attachment to a support surface;   wherein the module is configured to rest on a support surface;   wherein adjacent columns and respective bottom edges of the perimeter beams define an opening configured to receive a wall in-fill assembly; and   wherein each of the horizontal slab, the corner columns, the perimeter beams and the transverse ribs are fabricated from rebar-reinforced concrete and the module is fabricated as a unitary body.   
     
     
         2 . The module of  claim 1 , wherein the longitudinal edges are the same length as the transversal edges. 
     
     
         3 . The module of  claim 1 , wherein the longitudinal edges are twice as long as the transversal edges. 
     
     
         4 . The module of any one of  claims 1  to  3 , further comprising lifting anchors located at an upper surface of the horizontal slab adjacent each corner column. 
     
     
         5 . The module of  claim 1 , further comprising:
 two central columns, each said central column being located at a midpoint in each respective longitudinal edge, wherein the longitudinal edges are twice as long as the transversal edges; and   a central beam extending between the two central columns.   
     
     
         6 . The module of  claim 5 , further comprising lifting anchors located on the upper surface of the horizontal slab adjacent each corner column and each central column. 
     
     
         7 . The module of any one of  claims 1  to  6 , wherein the transverse ribs have a T-shaped cross-sectional profile. 
     
     
         8 . The module of any one of  claims 1  to  7 , wherein the support surface is an upper surface of a horizontal slab of one or more additional modules. 
     
     
         9 . The module of any one of  claims 1  to  7 , wherein the support surface is a base slab. 
     
     
         10 . The module of any one of  claims 1  to  7 , wherein the supporting surface comprises pre-cast footings adapted to support the base of a respective column, wherein the pre-cast footing comprises:
 a pre-cast reinforced concrete base formed as square concrete body, 
 a footing post extending upward from the concrete base and having an upper surface; and 
 four bolts extending from the upper surface of the footing post. 
 
     
     
         11 . The module of  claim 10 , wherein the concrete base and footing post of the pre-cast footing are cast as a unitary body. 
     
     
         12 . The module of any one of  claims 1  to  10  wherein the attachment element is a cast-in attachment element. 
     
     
         13 . The module of  claim 12 , wherein the cast-in attachment element is configured for attachment via a connector assembly to a corresponding attachment element on the supporting surface. 
     
     
         14 . The module of  claim 13 , wherein the connector assembly comprises a top bracket connected to a top connector baseplate and a bottom bracket connected to a bottom connector baseplate, wherein the top bracket and the bottom bracket are coupled via a pin connection. 
     
     
         15 . The module of any one of  claims 1  to  14 , further comprising one or more bolt inserts located on one or more externally facing surfaces of the corner and/or central columns, an upper surface of the horizontal slab, and/or a lower surface of the horizontal slab, wherein the bolt inserts are configured to receive structural or functional elements. 
     
     
         16 . The module of any one of  claims 1  to  15 , wherein the wall in-fill assembly is configured to receive one or more decorative elements, structural elements or functional elements, wherein the one or more structural elements or functional elements are selected from a window unit, a door unit, wall panels, and insulation. 
     
     
         17 . The module of  claim 16 , further comprising one or more bolt inserts located on an inner perimeter of the opening, wherein the bolt inserts are configured to receive the wall in-fill assembly. 
     
     
         18 . The module of  claim 15  or  17 , wherein the bolt inserts are cast-in bolt inserts. 
     
     
         19 . The module of any one of  claims 1  to  18 , further comprising external elements selected from decorative or insulating panels, railings, solar panels, wind turbines, water retention or management features. 
     
     
         20 . The module of any one of  claims 1  to  19 , wherein the perimeter beams further comprise service access openings of suitable size and shape to provide service access and/or to receive utility infrastructure. 
     
     
         21 . The module of any one of  claims 1  to  20 , wherein each corner column comprises a plurality of vertical rebar elements, each said vertical rebar element being a headed bar comprising a square plate washer welded at a top end of the respective vertical rebar element for connection to the slab. 
     
     
         22 . The module of any one of  claims 1  to  21 , further comprising a vertical indentation extending around an upper outer perimeter of each module. 
     
     
         23 . The module of  claim 22 , further comprising a horizontal indentation extending around the upper surface around the outer perimeter of each module. 
     
     
         24 . The module of any one of  claims 1  to  23 , further comprising sealing means configured to provide sealing engagement between adjacent modules upon installation. 
     
     
         25 . The module of any one of  claims 1  to  24 , wherein the module is sized for transport on a standard sized tractor trailer. 
     
     
         26 . A method for fabricating a reinforced concrete module, comprising the steps of:
 providing an array of rebar cages comprising a horizontal slab cage, four corner column cages, four perimeter beam cages, and at least two transversal rib cages;   assembling the array into a rebar framework for a desired module configuration within a formwork, wherein the rebar framework and formwork are in an upside-down configuration;   casting a concrete slurry into the formwork; and   allowing the concrete slurry to cure in the formwork for a period of time sufficient to form the reinforced concrete module.   
     
     
         27 . The method of  claim 26 , wherein the assembly of rebar cages further comprises two central column cages and a central beam cage. 
     
     
         28 . The method of  claim 26  or  27 , wherein the formwork further comprises one or more bolt inserts on an inner surface of the formwork. 
     
     
         29 . The method of any one of  claims 26  to  28 , wherein the casting step is carried out in a single pour. 
     
     
         30 . A transport frame configured to support one or more modules as defined in any one of  claims 1  to  25  on a transport vehicle, the transport frame comprising:
 first and second pairs of support legs, each of said support legs being vertically oriented and having a telescopic leg insert configured to extend out of the respective support leg in an upward direction; 
 a first lateral bracing beam extending between each respective leg of said first pair of support legs; 
 a second lateral bracing beam extending between each respective leg of said second pair of support legs; 
 first and second longitudinal bracing beams extending between said first and second pairs of support legs; 
 a first horizontal support beam extending between and attached to a top end of the telescopic leg inserts of the first pair of support legs; and 
 a second horizontal support beam extending between and attached to a top end of the telescopic leg inserts of the second pair of support legs; 
 the first and second horizontal support beams each comprising a telescopic arm insert configured to extend outwardly from each end of the respective support beams. 
 
     
     
         31 . The transport frame of  claim 30 , wherein a hydraulic cylinder is provided inside each of the support legs to lift and lower the telescopic leg inserts. 
     
     
         32 . The transport frame of  claim 30  or  31 , wherein a hydraulic cylinder is provided inside each of the support beams to extend and retract the telescopic arm inserts.