MODULAR BUILDING SYSTEM AND METHOD
A modular building unit for use in constructing a building comprises a top, a base, two opposed ends and at least one open side. The at least one open side extends between the two opposed ends and is free of upwardly extending structural supports. The modular building unit is configured to be interconnected to a second modular building unit along the at least one open side. The building unit is dimensioned to enable the building unit to be accommodated at or within a predetermined width limit for transportation before assembly and the building unit and the second modular building unit, when assembled, exceeding the predetermined width limit.
The following relates to a modular building system and method. The system includes modular units that may be constructed at a manufacturing facility and then be transported to a construction site for assembly.
BACKGROUNDThe power plants and computer rooms of buildings are often large and complex systems with a large amount of interconnected equipment. These systems can be incorporated into a main building. However, it may be advantageous to house such facilities in a separate building. This allows the main building to be reserved for other uses and allows easier access to the equipment in the separate building.
The complexity of the systems also means that it may be advantageous to assemble, interconnect and test the equipment in a manufacturing facility and then ship the completed system to the construction site. One way this has been done is to use a shipping container as a building in which to assemble the equipment. The equipment is assembled and tested and then shipped to the construction site to be interconnected to the main building.
A limitation on this approach is the size of a standard shipping container. A standard shipping container may be 8′×8′×40′. If the equipment to be assembled requires more space, a second shipping container is used. The result is that that the equipment is housed in a number of different 8′×8′×40′ building. This limits accessibility to installed equipment, limits the type of cooling system that can be used, and is unattractive.
SUMMARY OF THE INVENTIONAccording to one aspect of the present invention, there is provided a modular building unit for use in constructing a building comprising: a top, a base, two opposed ends and at least one open side, the at least one open side extending between the two opposed ends and being substantially free of structural supports; the modular building unit being configured to be interconnected to a second modular building unit along the at least one open side; and the building unit being dimensioned to enable the building unit to be accommodated at or within a predetermined width limit for transportation before assembly and the building unit and the second modular building unit, when assembled, exceeding the predetermined width limit.
In some embodiments the building unit comprises at least one roof truss interconnecting the top and the two opposed ends.
In some embodiments the at least one roof truss comprises a plurality of roof trusses.
In some embodiments the modular building unit comprises at least one base truss interconnecting the base and the two opposed ends.
In some embodiments the at least one base truss comprises a plurality of base trusses.
In some embodiments the modular building unit comprises fixtures along the sides, adjacent the sides, for attaching lines for lifting the modular building unit.
In some embodiments the roof trusses and the base trusses comprise substantially flat trusses.
In some embodiments the roof trusses and the base trusses are spaced to prevent deformation of the modular building unit when lifted by the lines.
In some embodiments a white space for computer equipment comprises a plurality of modular building units.
In some embodiments the modular building unit comprises computer hardware racks mounted to the base.
In some embodiments the opposed ends comprise walls.
In some embodiments at least one open side comprises at least one of internal flanges and external flanges for interconnecting the modular building unit to the second modular building unit.
In some embodiments the modular building unit comprises floor tiles covering the base trusses.
In some embodiments the base trusses comprise openings for at least one of an in-floor air distribution system, an in-floor electrical distribution system and an in-floor mechanical distribution system.
In some embodiments the roof trusses are positioned to accommodate at least one of an air distribution system, an electrical distribution system and a mechanical distribution system.
According to another aspect of the present invention, there is provided a modular system for construction of a building comprising: two end building units comprising a roof, a base, two opposed ends and one open side; the building units being configured to be interconnect along the open sides, the open sides of the building units being substantially free of upright structural supports; the building units being dimensioned to enable the building units to accommodated at or within a predetermined width limit for transportation before assembly and the building, when assembled, exceeding the predetermined width limit.
In some embodiments the modular system further comprises at least one intermediate building unit comprising a roof, a base, two opposed ends and two open sides, the at least one intermediate building unit being located between the two end building units.
In some embodiments the at least one intermediate building unit comprises a plurality of intermediate building units.
According to still another aspect of the present invention, there is provided a method of constructing a building comprising: providing a plurality of modular building units, each of the building units comprising: a roof, a base, two opposed ends and at least one open side, the at least one substantially open side extending between the two opposed ends and being free of structural supports; the modular building units being configured to be interconnected to others of the modular building units along the at least one open side; the building units being dimensioned to enable the building units to be accommodated at or within a predetermined width limit for transportation before assembly and the building unit and the second modular building unit, when assembled, exceeding the predetermined width limit; transporting the plurality of modular building units to a building site; successively positioning the modular building units side-by-side; interconnecting the modular building units.
Other aspects and features of the present invention will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific embodiments of the invention.
The invention will now be described in greater detail with reference to the accompanying drawings, in which:
The units 8, 10 and 12 have a base 14, a roof 16 and two opposed end walls 18. The first side unit 8 also has a first side wall 20. The second side unit 12 also has a second side wall 22. In
As noted above, the units 8, 10 and 12 include a base 14. In the present embodiment, the base 14 is formed with a frame 24 (
In this embodiment, the base 14 is rectangular with short opposed ends 32. End posts 34 are provided at the four corners of the base 14 along the opposed ends 32. Two end posts 34 are also located at an intermediate position along the opposed ends 32. The end posts 34 of the present embodiment are upright posts which extend from the base 14 to the top which has the roof 16. The end posts 34 may be, for example, welded or bolted to the base 14. The tops of the end posts 34 are connected to end roof members 36. The end roof members 36 of this embodiment extends horizontally above the opposed ends 32 and define the ends of the roof 16.
In this embodiment, the intermediate unit 10 of
Side roof members 40 extend along the un-open sides of the first and second end units 8 and 12 and connect to the top of the corner end posts 34 of the side walls 20 and 22. The un-open sides have side posts 42 behind the first side wall 20 and the second side wall 22. In this embodiment, the side posts 42 are upright and extend from the base 12 to side roof members 40. In the second side unit 12, two of the side posts 42 also define a door opening 44.
The general framing described in respect of this embodiment is exemplary only. Other framing that includes differing structure such as diagonal side and end members may also be used. The posts may also be eliminated if structured strength is provided by the walls.
In this embodiment, the units 8, 10 and 12 have lengthwise roof trusses 46, crosswise roof trusses 48 and lengthwise base trusses 50. The lengthwise roof trusses 46 extend between the opposed ends 32 are connected to the end posts 34. In this embodiment, the roof trusses 46 comprise a continuous unit. The crosswise roof trusses 48 are pairs of trusses that are connected between the lengthwise roof trusses 46 at right angles.
In this embodiment, the units 8, 10 and 12 all have a pair of crosswise roof trusses 48 extending parallel to and intermediate the opposed ends 32. The intermediate unit 10 has three lengthwise roof trusses 46 extending between the tops of the opposite end posts 32. The three lengthwise roof trusses 46 are connected at their intermediate peak by the pair of crosswise roof trusses 48. The end units 8 and 12 have a similar configuration but do not have lengthwise roof trusses 22 along their walls 20 and 22 respectively.
The base trusses 50 are shown in
In this embodiment, the lengthwise roof trusses 46 are flat bottomed and are peaked on top to follow the roof line. The crosswise roof trusses 48 and the base trusses 50 are flat on top and bottom. The trusses 46, 48 and 50 have triangular positioned struts angled at 60° to each other. In this embodiment, the roof trusses 22 are spaced at six foot intervals parallel to the open sides 38 and the base trusses 50 are spaced at two foot intervals, also parallel to the open sides 38. The roof trusses 46 and 48 of this embodiment may have a height of approximately 20 inches and the base trusses 50 of this embodiment may have a height of approximately 8 inches. In this embodiment, the base trusses 50 may incorporate rectangular openings 54 to allow piping or other conduits to extend through the base trusses 50 under the floor plate 52.
The truss designs and layouts described above are exemplary only. Numerous truss designs and layouts exist that which performed the required function of allowing the units 8, 10 and 12 to be constructed and transported with open sides 38. In some embodiments, some or all of the trusses 46, 48 and 50 may be altered or eliminated. Any truss design and positioning that supports the modular building units 8, 10 and 12 for transport and installation with open sides 38 at least substantially open may be used. Designs that include some members extending across the open sides 38, such as braces in the upper corners, are also contemplated by the invention.
The connection of the members may be made by known means. For example, the end posts 34 may be, welded or bolted to the base 14. The end walls 18 may be connected to the end posts 34, for example, by welding, bolting or by being wrapped around the corner end posts 34. The end walls 18 may, for example, be formed of corrugated metal such as corrugated steel. Other embodiments may not be rectangular and may, for example, be rounded or irregular in shape.
As noted above, the unit 10 comprises a base 14 with a frame 24. The frame 24 of this embodiment includes side faces 62. Spaced along the side faces 62 are lifting points 64. In this embodiment, there are four lifting points 64 spaced along the side faces 62 of the two open sides 38. The lifting points 64 are pairs of angled plates with a hole 66 there through that are connected to the base 14 and angled towards each other at an approximately 45° angle. The lifting points 64 may be of a different number and configuration such as eye bolts. They may be differently positioned, for example on the base 14, posts 34 or roof 16. They may also be eliminated and a different lifting means used.
The rigging 60 of this embodiment includes two pairs of straps or lower lines 68 for connection to each of the lifting points 64 through the holes 66. In some embodiments, the pairs of lifting points 64 are positioned to give an approximately 60° angle between each of the lower lines 68 and the base 14. The lower lines 68 are collected by pulleys 70 to cross-members 72. The cross-members 72 connect to the pulleys 70 on opposite sides 38 of the modular building unit 10. The ends of the cross-members 72 are in turn connected to pairs of upper lines 74. The upper lines 74 from each of the cross-member 72 meet at ends of an upper member 76. The rigging 60 is symmetrical to allow a balanced load support for the modular building unit 10.
In this embodiment, the modular building unit 80 has lifting points 94. The lifting points 94 of the modular building unit 80 are on the roof 86 rather than the base 82, in contrast to the positioning of the lifting points 64 on the modular building unit 10. In this embodiments, there are eight lifting points 94 each having a hole there through. Four of the lifting points 94 are vertically aligned with the top of four of the upright posts 88 and four of the lifting points 94 are vertically aligned with the top of four of the support posts 91. The upright posts 88 and the support posts 91 may provide rigidity to prevent deformation of the modular building unit 80 when lifted by the lifting points 94.
The shape and structure of the modular building unit 80 may be altered, include trusses, have different attachment points for rigging and may include different equipment. The modular building unit 80 may also be eliminated.
In other embodiments, more or fewer modular building units with at least one open side may be used. For example, any number of building units from one to tens or more with two open sides, such as modular building unit 10 may be used to make any size of building. Alternatively, modular building unit 10 may be eliminated and modular building units 8 and 12, with facing open sides, may be used to provide a smaller open room.
The joining of the walls of the two portions 114 of the modular building unit is shown in
The joining of the roofs of the two portions 114 of the modular building unit is shown in
In this embodiment, an additional seal is used where the peak of the roofs join.
The final fastening elements of this embodiment are the unit joining clips 120. As shown in
Some or all of these joining means may be altered or eliminated. For example, it will be appreciated that the weight of the units may prevent their relative movement and caulking or other weather sealing of the seams between the units may be sufficient.
In embodiments which include the base trusses 50, the base trusses 50 may be are covered by the floor 140. The floor may be assembled to the modular building unit 10 either at the factory or at the end location. The floor 140 may be a computer room raised floor tile. An in-floor air distribution system may be installed under the floor 140, between and/or through the trusses 50. Electrical, air distribution and mechanical distribution systems may be run in either or both of the base and roof truss systems. Conduits, both for water and electrical or other functions may be run between the floor 140 and the base 12 in the space created by the trusses 24 through the openings 54.
In some embodiments computer equipment 138 racks are installed to the floor at the factory and the modular building units 8, 10 and 12 are transported with both the floor and computer equipment racks in place to further reduce the assembly required with the modular building units 10 are installed at their final destination. As can be seen in
In some embodiments, the modular building units 8, 10 and 12 are 30 to 50 feet long, 10 to 20 feet wide and 8 to 12 feet high. The width and length of the modular building units 8, 10, 12, 80 and 110 are each sized to be transported within a predetermined width limit for transportation. For example, the maximum dimensions for transportation by road may be 50 feet long, 20 feet wide and 12 feet high. If the modular building units 8, 10, 12, 80 and 11 are each this size, they can be transported by road when unassembled but the resulting building, when assembled, is too large and exceeds the predetermined width limit when assembled.
What has been described is merely illustrative of the application of the principles of the invention. Other arrangements and methods can be implemented by those skilled in the art without departing from the spirit and scope of the present invention.
Claims
1. A modular building unit for use in constructing a building comprising:
- a top, a base, two opposed ends and at least one open side,
- the at least one open side extending between the two opposed ends and being substantially free of structural supports;
- the modular building unit being configured to be interconnected to a second modular building unit along the at least one open side; and
- the building unit being dimensioned to enable the building unit to be accommodated at or within a predetermined width limit for transportation before assembly and the building unit and the second modular building unit, when assembled, exceeding the predetermined width limit.
2. The modular building unit of claim 1 wherein the building unit comprises at least one roof truss interconnecting the top and the two opposed ends.
3. The modular building unit of claim 2 wherein the at least one roof truss comprises a plurality of roof trusses.
4. The modular building unit of claim 1 further comprising at least one base truss interconnecting the base and the two opposed ends.
5. The modular building of claim 4 wherein the at least one base truss comprises a plurality of base trusses.
6. The modular building unit of claim 2 further comprising at least one base truss interconnecting the base and the two opposed ends.
7. The modular building of claim 6 wherein the at least one base truss comprises a plurality of base trusses.
8. The modular building unit of claim 7 further comprising fixtures along the sides, adjacent the sides, for attaching lines for lifting the modular building unit.
9. The modular building unit of claim 7 wherein the roof trusses and the base trusses comprise substantially flat trusses.
10. The modular building unit of claim 8 wherein the roof trusses and the base trusses are spaced to prevent deformation of the modular building unit when lifted by the lines.
11. A white space for computer equipment comprising a plurality of modular building units according to claim 1.
12. The modular building unit of claim 11 further comprising computer hardware racks mounted to the base.
13. The modular building unit of claim 1 wherein the opposed ends comprise walls.
14. The modular building unit of claim 13 wherein the at least one open side comprises at least one of internal flanges and external flanges for interconnecting the modular building unit to the second modular building unit.
15. The modular building unit of claim 7 further comprising floor tiles covering the base trusses.
16. The modular building unit of claim 15 wherein the base trusses comprise openings for at least one of an in-floor air distribution system, an in-floor electrical distribution system and an in-floor mechanical distribution system.
17. The modular building unit of claim 3 wherein the roof trusses are positioned to accommodate at least one of an air distribution system, an electrical distribution system and a mechanical distribution system.
18. A modular system for construction of a building comprising:
- two end building units comprising a roof, a base, two opposed ends and one open side;
- the building units being configured to be interconnect along the open sides,
- the open sides of the building units being substantially free of upright structural supports;
- the building units being dimensioned to enable the building units to accommodated at or within a predetermined width limit for transportation before assembly and the building, when assembled, exceeding the predetermined width limit.
19. The modular system of claim 18 further comprising at least one intermediate building unit comprising a roof, a base, two opposed ends and two open sides, the at least one intermediate building unit being located between the two end building units.
20. The modular system of claim 18 wherein the at least one intermediate building unit comprises a plurality of intermediate building units.
21. A method of constructing a building comprising:
- providing a plurality of modular building units, each of the building units comprising:
- a roof, a base, two opposed ends and at least one open side, the at least one substantially open side extending between the two opposed ends and being free of structural supports;
- the modular building units being configured to be interconnected to others of the modular building units along the at least one open side;
- the building units being dimensioned to enable the building units to be accommodated at or within a predetermined width limit for transportation before assembly and the building unit and the second modular building unit, when assembled, exceeding the predetermined width limit;
- transporting the plurality of modular building units to a building site;
- successively positioning the modular building units side-by-side;
- interconnecting the modular building units.
Type: Application
Filed: May 6, 2011
Publication Date: Nov 8, 2012
Applicant: EPSILON INDUSTRIES INC. (Kingston)
Inventors: Chris Wiederick (Kingston), Darryl Gillespie (Kingston), Steve McAllister (Amherstview), Bruce Johnston (Hartington)
Application Number: 13/102,178
International Classification: E04H 1/00 (20060101); E04G 21/14 (20060101);