STRUCTURAL BRACE FOR MODULAR HOUSING MODULE

Abstract

A structural brace for a pre-fabricated housing module includes (a) a temporary beam connecting two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module; (b) ceiling bracing panels each providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and (c) wall bracing panels each providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module. A further transverse beam may be provided to connect the ceiling bracing panels for greater structural support and to facilitate lifting of the module during transportation. A tarp may be provided to cover the top and exposed sides of the pre-fabricated housing module to prevent damage to the interior on route to an installation site.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to prefabricated housing modules. In particular, the present invention relates to structural support for transporting a prefabricated housing module from its manufacturing site to its installation site.

2. Discussion of the Related Art

Prefabricated housing derives its cost advantage by performing many of the assembly steps required for a housing unit at the factory, rather than at the job site. The building block for multi-unit prefabricated housing is typically the individual pre-fabricated modules. A typical module may include one or more bedrooms, a living room, a kitchen and a bathroom. Each module, typically including all of its exterior and interior walls, is manufactured and assembled at a manufacturing facility and transported to the building site for further assembly (if required) and for installation into the multi-unit structure. At a building site, a concrete foundation is typically prepared, to which a pre-fabricated module is attached and fastened. Typically, for efficiency reasons, the pre-fabricated module and the foundation are both provided means for the attachment and fastening ahead of the installation time. For a multi-story unit, a second floor module is then stacked on top of and fastened to the first floor unit. If the multi-unit structure has additional stories, additional modules are similarly stacked and fastened to the story immediately underneath. If the multi-unit design includes abutting side by side modules, the abutting modules are placed along side each other and fastened along the abutting exterior walls.

It is not unusual to transport a prefabricated module hundreds of miles to an installation site. Therefore, the prefabricated module must have structural integrity that can withstand the forces experienced on the road. Typically, structural integrity is provided by the module's exterior load-bearing side walls and a structural floor and a structural ceiling. As a result, a multi-unit housing unit built with these modules has both a structural floor and a structural ceiling between two floors, and two load-bearing walls between abutting side by side units. In contrast, in custom-built housing, structural integrity can be provided by a single load-bearing structure between floors or between side by side adjacent units. The redundant walls, ceilings and floors in prefabricated modules add significant cost, and because the redundancy is not needed in the final building structure, the additional material is wasted.

SUMMARY

According to one embodiment of the present invention, a structural brace for a pre-fabricated housing module includes (a) a temporary beam connecting two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module; (b) ceiling bracing panels each providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and (c) wall bracing panels each providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module. A further transverse beam may be provided to connect the ceiling bracing panels for greater structural support and to facilitate lifting of the module during transportation. A tarp may be provided to cover the top and any exposed side of the pre-fabricated housing module to prevent damage to the interior on route to an installation site.

According to one embodiment of the present invention, a ceiling bracing panel includes a base board and a number of dimensional lumber pieces secured to the base board which are placed substantially parallel to each other and spaced at predetermined intervals. A wall bracing panel may be similarly provided.

The structural brace of the present invention may include steel blocks that secure the ceiling panels to the studs of a side wall of the pre-fabricated housing module, so as to allow the side wall to bear the weight of the pre-fabricated housing module when it is moved. Additional structural support is achieved using hold downs bolted to structural elements of the side wall. Sound deadened steel plates may be provided for reducing sound and vibration during transportation.

n one embodiment, the structural brace of the present invention is a temporary structure that provides structural strength to the prefabricated housing unit, as the prefabricated housing unit is moved between manufacturing and installation sites. Possibility of the housing unit suffering damages on route to the building site is therefore greatly reduced. The structural brace is removed at the time of installation. The removed structural brace can be returned to the manufacturing facilities to be reused. The structural brace of the present invention therefore eliminates need for redundant walls, floors and ceilings, thus reducing the waste, as compared to the prior art.

The present invention is better understood upon consideration of the detailed description below and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows prefabricated housing module 100 before being provide a structural brace.

FIG. 2 shows prefabricated module 100 of FIG. 1 being provided a structural brace for maintaining structural integrity during transportation, in accordance with one embodiment of the present invention.

FIG. 3 shows tarp 300 being provided over module 100 to provide a covering for module 100 during transportation between the manufacturing facilities and the building site.

FIG. 4 is an axonometric view of ceiling panel 201.

FIG. 5 shows a cross section of installed structural brace 200.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to one embodiment of the present invention, a structural brace is developed to provide a prefabricated housing module structural integrity during transportation between a manufacturing facility and a building site where the module is to be installed.

FIG. 1 shows prefabricated housing module 100 before being provided a structure brace. As shown in FIG. 1, prefabricated module 100 is open at one side wall and is not provided a structural ceiling. Module 100 includes permanent prefabricated external side walls 101a, 101b and 101c, and a structural floor 108. Window frames 102 have been provided and installed in external side walls 101a and 101b. Module 100 also includes multiple rooms with multiple interior dividing walls 103 installed at the manufacturing facilities. Module 100 is a “building envelop,” to which other interior amenities, such as cabinets, closets, stairs and plumbing connections, are installed at the building site. These other amenities may be separately manufactured at different manufacturing facilities (or supplied by other vendors) and provided as modular “cells” for installation at the building site.

According to the present invention, as module 100 is a unit which abuts a neighboring unit on one of its sides and with another unit stacked on top, a structural side wall and a structural ceiling is not included. At the building site, module 100 is attached and fastened on its open side to another unit that has a structural side wall. Similarly, at the building site, another module with a structural floor is attached and fastened to the open top to module 100, so that the structural floor of the other unit provides the ceiling for module 100. According to this design, therefore, redundant ceilings and side walls are eliminated to achieve material efficiency.

FIG. 2 shows prefabricated housing module 100 being provided structural brace 200 for maintaining structural integrity during transportation, in accordance with one embodiment of the present invention. As shown in FIG. 2, structure brace 200 includes temporary beam 204, ceiling bracing panels 201 and wall bracing panels 202. Ceiling bracing panels 201 are held down by steel blocks and hold downs secured on the studs of external side wall 101b (see FIG. 5). In addition, ceiling bracing panels 201 are connected in a transverse direction by standard size dimensional lumber 203 (shown in FIG. 3). Standard size dimensional lumber 203 may be provided, for example, by a 2×6 piece (i.e., two inches by six inches). FIG. 3 shows tarp 300 being provided over module 100 to provide a covering for module 100 during transportation between the manufacturing facilities and the building site, to be removed immediately prior to installing module 100 at the building site. Tarp 300 protects the interior of prefabricated module 100 against external elements by covering the open ceiling and side. As shown in FIG. 3, module 100 can be moved by a crane using steel cables which are attached to the load-bearing structures provided on structural braces 200.

FIG. 4 is an axonometric view of ceiling panel 201. As shown in FIG. 4, ceiling bracing panel 201 includes a base board 401, which can be provided by a ½-inch thick plywood board. On base board 401 is provided 2″×4″ dimensional lumber pieces spaced at 24″ apart (on center). Wall bracing panels 202 can be similarly constructed.

FIG. 5 shows a cross section of installed structural brace 200. As shown in FIG. 5, ceiling bracing panel 201 is secured on one side to external side wall 101b, which may be provided by a conventional double stud party wall, and on the other side to wall bracing panel 202. Steel blocks 501 are secured to the double stud party wall 504 by ⅝″ bolts (indicated by reference numerals 503), so that the weight of module 100 can be borne in the studs in the wall. In addition, hold-downs 505 (e.g., HD5A or HTT16) may be provided for further support by horizontal members in the double stud party wall. Ceiling bracing panel 201 and wall bracing panel 202 are attached to temporary beam 204, which may be provided by 4″×8″ dimensional lumber 505.

As discussed above, wall bracing panel 202 may be provided substantially the same structure as ceiling bracing panel 201 (e.g., dimensional lumber (e.g., 2×4's) secured to a base board and spaced apart at regular intervals). A riser (indicated by reference numeral 507) having, for example, the construction of small sections of a double stud party wall, may be provided from floor 108 of prefabricated module 100 to allow wall brace panel 202 to attach. Such a riser structure would allow wall brace panel 100 to be attached to module 100 in substantially the same manner as ceiling panel 201 attaches to side wall 101b. In one embodiment, sound deadened steel (SDS) plates 506 are provided for attachment to floor 108 of module 100 to limit sound and vibrations in wall bracing panel 202.

The detailed description above is provided to illustrate specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modifications within the scope of the present invention are possible. The present invention is set forth in the following claims.

Claims

1. A structural brace for a pre-fabricated housing module, comprising:

a temporary beam connecting two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module.

a plurality of ceiling bracing panels, each ceiling bracing panel providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and

a plurality of wall bracing panels, each wall bracing panel providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module.

2. A structural brace as in claim 1, further comprising a transverse beam connecting the plurality of ceiling bracing panels.

3. A structural brace as in claim 1, further comprises a tarp covering for the top of the pre-fabricated housing module.

4. A structural brace as in claim 1, wherein each ceiling bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.

5. A structural brace as in claim 1, wherein each wall bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.

6. A structural brace as in claim 1, further comprises steel blocks secured to the ceiling panels and the third side wall, so as to allow the third side wall to bear the weight of the pre-fabricated housing module when the pre-fabricated housing module is moved.

7. A structural brace as in claim 6, wherein the steel blocks are bolted to studs provided in the third side wall.

8. A structural brace as in claim 7, further comprises hold downs bolted to structural elements of the third side wall.

9. A structural brace as in claim 1, further comprises sound deadened steel plates for reducing sound and vibration during transportation.

10. A method for providing a structural brace for a pre-fabricated housing module, comprising:

providing a temporary beam to connect two opposite side walls of the pre-fabricated housing module along an open side of the pre-fabricated housing module.

providing a plurality of ceiling bracing panels, each ceiling bracing panel providing horizontal temporary structural support between a third side wall of the pre-fabricated housing module and the temporary beam; and

providing a plurality of wall bracing panels, each wall bracing panel providing temporary vertical structural support between the temporary beam and a floor of the pre-fabricated module.

11. A method as in claim 10, further comprising providing a transverse beam to connect the plurality of ceiling bracing panels.

12. A method as in claim 10, further comprises providing a tarp to cover the top of the pre-fabricated housing module.

13. A method as in claim 10, wherein each ceiling bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.

14. A method as in claim 10, wherein each wall bracing panel comprises a base board and a plurality of dimensional lumber pieces secured to the base board, placed substantially parallel to each other and spaced at predetermined intervals.

15. A method as in claim 10, further comprises providing steel blocks secured to the ceiling panels and the third side wall, so as to allow the third side wall to bear the weight of the pre-fabricated housing module when the pre-fabricated housing module is moved.

16. A method as in claim 15, wherein the steel blocks are bolted to studs provided in the third side wall.

17. A method as in claim 16, further comprises hold downs bolted to structural elements of the third side wall.

18. A method as in claim 10, further comprises providing sound deadened steel plates to reduce sound and vibration during transportation.