Modular building structure
Disclosed herein is a modular building structure. The structure includes a modular building roof structure comprising the roof structure which includes a plurality of truss structures each having a top and a bottom and a pair of deck layers attached to and for transversely spanning the tops of the truss structures. The roof structure also includes an acoustical ceiling suspended along the bottoms of the truss structures. The building structure also includes a modular building floor structure which comprises a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent each other to create a plurality of spaced apart support channels. In a preferred embodiment, the deck structure is oriented transverse to the support beams. The floor structure further includes a plurality of support beams for supporting the deck structure. Significantly, the deck and the acoustical ceiling define a return air plenum that provides for proper venting, distribution and circulation of air, including introduction of fresh air, throughout the modular structure. Advantageously, no separate ductwork or duct system is required with the use of the air plenum. Preferably, the structure is substantially non-combustible and mold-resistant.
This invention relates generally to modular building systems, and more particularly to modular building roof and floor structures.
Modularly constructed building structures are advantageous in that they provide shelter from the elements in which a variety of activities can be housed, and are relatively easily transported from one locale to another. Moreover, such structures can typically be assembled in stackable sections, or sections placed side-by-side (i.e., the sections are positioned adjacent each other), right on site after being transported. Modular building structures can be used for production of single and multi-unit or multi-family homes, as well as apartments, condominiums, classrooms, general offices, medical facilities, commercial buildings and the like.
Many modular building structures are custom designed. However, building structures can also be designed according to standard or pre-fabricated building templates as well. Today's modular building structures are computer-engineered to meet national building codes. They can be precisely engineered for increased structural durability. High quality can be maintained by inspection during construction process. In one construction example, a modular building structure is delivered to a desired site, after which individual modular structures or “modules” are assembled into an overall modular building structure.
In general, the metrics of building construction costs break out on a per square foot basis. It is a continuous goal to reduce the construction costs of the modular structures. To this end, it would be desirable to provide a modular building structure that, while meeting all applicable building codes and other standards, is simpler to construct than known modular building structures. For example, a building structure comprising fewer pieces, parts or other components in its construction is desirable. Similarly, material selection for such modular building structures is key, in that the material type and placement can result in a building structure of having a greater useful life and durability.
It would also be desirable to use stronger and more durable modules or substructures in making the overall modular building structure. This can lead to a decrease in the number of supports or braces in a given area, thereby reducing modular building structure costs on a square foot basis. Advantageously, the mating of various components can provide increased strength, which, in conjunction with the reduction in the number of support structures, reduces overall modular weight, in addition to construction and transportation costs.
Further, in the modular building structure industry, there are increasing requirements aimed at improving the structure resistance to mold and combustion. Accordingly, it would be desirable to provide a modular building structure that increases the used of stainless steel materials in order to achieve these desired ends.
BRIEF SUMMARY OF THE INVENTIONAn inventive modular building structure is disclosed herein. In one embodiment, a modular building roof structure in combination with an acoustical ceiling is disclosed, the combination comprising a modular building roof structure comprising a plurality of truss structures each having a top and a bottom; a pair of deck layers attached to and for transversely spanning the tops of the truss structures; and an acoustical ceiling suspended along the bottoms of the truss structures; wherein the deck and the acoustical ceiling define a return air plenum.
In another embodiment, a modular building floor structure is disclosed comprising a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent each other to create a plurality of spaced apart support channels; and a plurality of support beams for supporting the deck structure. In a preferred embodiment, the deck structure is oriented transverse to the support beams.
And in another embodiment, a modular building structure is disclosed comprising a modular building roof structure in combination with a suspended acoustical ceiling system, the combination comprising a modular building roof structure comprising a plurality of truss structures each having a top and a bottom; a pair of deck layers attached to and for transversely. spanning the tops of the truss structures; and an acoustical ceiling suspended along the bottoms of the truss structures; and a modular building floor structure comprising a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent each other to create a plurality of spaced apart support channels; and a plurality of support beams for supporting the deck structure; wherein the deck and the acoustical ceiling define a return air plenum. In a preferred embodiment, the deck structure is oriented transverse to the support beams.
Other objects, aspects, and advantages of the invention will be apparent upon a thorough reading of the detailed description below along with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGSEmbodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in its application to the details of construction or the arrangement of the components illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components.
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Significantly, the deck 52 and the suspended acoustical ceiling define a return air plenum space 56. The return air plenum space 56, in combination with any physical vents, provides for proper venting, distribution and circulation of air, including introduction of fresh air, throughout the modular structure. As a result of the present structural arrangement, no separate ductwork or duct system is required, which provides savings in the manufacture, both in terms of material and labor costs, of the modular building structure of the present invention. Preferably, at least one of the plurality of longitudinal, open web trusses, the plurality of tubular columns, and the roll-formed deck can be constructed of steel, and in a preferred embodiment, the deck 52 is substantially covered with a mold-resistant foam insulation material 57. Accordingly, the modular building roof structure 32 can be described as substantially non-combustible and substantially mold-resistant.
The modular building structure 10 further includes a modular building floor structure 34 which is joined or connected to the roof structure 32 as shown via columns 42. The floor structure 34 includes a single layer deck structure 58. A plurality of longitudinal main support beams 60, also called “Z purlins”, are connected to the deck pans and are oriented transverse to the length of the floor structure. Advantageously, the present invention provides for the ability of the support beams to be positioned in spaced apart fashion, typically about 12 to 14 feet apart over the entire length of the modular building unit. End support beams or “I-beams” 62 are utilized at the outer region of the floor structure. In one embodiment, a decking surface 64, typically of a plywood, cement board, poured concrete or combination type, can be connected to, positioned or laid over, or otherwise formed over, the pair of deck pans. As an additional feature, wheels 66 can be provided to improve the mobility of the modular unit.
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While the present invention has been described in terms of the preferred embodiment, it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
Claims
1. A modular building roof structure in combination with an acoustical ceiling, the combination comprising:
- a modular building roof structure comprising: a plurality of truss structures each having a top and a bottom; a pair of deck layers attached to and for transversely spanning the tops of the truss structures; and
- an acoustical ceiling suspended along the bottoms of the truss structures;
- wherein the deck and the acoustical ceiling define a return air plenum.
2. The combination of claim 1 wherein the trusses further comprise a plurality of longitudinally disposed supporting beams connected in overlapping relationship to a plurality of tension and compression members such that the trusses form a longitudinal, open web truss structure.
3. The combination of claim 1 wherein the pair of deck layers is roll-formed.
4. The combination of claim 1 wherein the pair of deck layers is corrugated.
5. The combination of claim 1 wherein the pair of deck layers is constructed of steel.
6. The combination of claim 1 wherein the modular building roof structure is at least one of substantially non-combustible and substantially mold-resistant.
7. The combination of claim 1 further wherein at least one of the plurality of longitudinal, open web trusses, the plurality of tubular columns, and the roll-formed deck comprise steel.
8. A modular building floor structure comprising:
- a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent to each other to create a plurality of spaced apart support channels; and
- a plurality of support beams for supporting the deck structure;
- wherein the deck structure is oriented transverse to the support beams.
9. The modular building floor structure of claim 8 further comprising a decking surface laid over the pair of deck pans.
10. The modular building floor structure of claim 9 wherein the decking surface includes plywood and wherein the plywood is supported at least in part by the support channels.
11. The modular building floor structure of claim 8 wherein the decking surface includes cement board and wherein the cement board is supported at least in part by the spaced apart support channels.
12. The modular building floor structure of claim 8 wherein the decking surface includes poured concrete and wherein the concrete is supported at least in part by the support channels.
13. The modular building floor structure of claim 8 wherein at least one of the upper and lower deck pans is corrugated.
14. The modular building floor structure of claim 8 wherein the deck structure is capable of supporting a greater load than each of one of the pair of deck pans individually.
15. The modular building floor structure of claim 8 wherein the deck structure has a combined deflection level that is less than an individual deflection level for each of the deck pans individually for a given load.
16. The modular building floor structure of claim 8 wherein the support members comprise at least one I-beam.
17. The modular building floor structure of claim 16 wherein the support members comprise two I-beams.
18. The modular building floor structure of claim 8 wherein the plurality of main support beams are spaced apart in intervals that are in a range of about 12 to about 14 feet.
19. A modular building structure comprising:
- a modular building roof structure in combination with a suspended acoustical ceiling system, the combination comprising: a modular building roof structure comprising: a plurality of truss structures each having a top and a bottom; a pair of deck layers attached to and for transversely spanning the tops of the truss structures; and an acoustical ceiling suspended along the bottoms of the truss structures; and a modular building floor structure comprising: a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent each other to create a plurality of spaced apart support channels; and a plurality of support beams for supporting the deck structure; wherein the deck and the acoustical ceiling define a return air plenum; and wherein the deck structure is oriented transverse to the support beams.
20. The modular building structure of claim 19 wherein the upper deck pan and the lower deck pan are separated to create a plurality of deck gaps, and further including a plurality of spacers inserted into the plurality of deck gaps.
21. The modular building structure of claim 19 further including inserting support materials into the plurality of spaced apart support channels for increasing the support strength of the deck structure.
22. The modular building structure of claim 19 wherein each modular building has a lateral load bearing characteristic, and that when a plurality of the modular buildings are placed laterally together to create a modular building group having a total lateral load bearing characteristic, the total lateral load bearing characteristic is additive from the individual modular building lateral load bearing characteristics.
23. The modular building structure of claim 19 wherein the pair of deck layers are separated to create a plurality of deck gaps, and further including a plurality of spacers inserted into the plurality of deck gaps.
Type: Application
Filed: May 5, 2004
Publication Date: Nov 10, 2005
Inventors: Rick Bedell (Bristol, IN), Paul Moss (Constantine, MI)
Application Number: 10/839,666