US3750366A - Building - Google Patents

Abstract

A building employing prefabricated room-enclosing modules which function also as box-shaped horizontal beams and ties for connecting vertical weight-supporting columns into a rigid framework. The columns are preferably concrete members which are poured in place into spaces formed between the modules. The inter-module spaces include vertical chases and horizontal plenums which are in communication with each other and with a heating/cooling plant output, to form an air jacket which surrounds each module over a plurality of its exterior surfaces, and operates as an effective radiant heat exchanger therewith. The heated or cooled air is ultimately discharged into the interior occupancy space of the modules, so as to provide a combination radiant and convective heating/cooling system. The interior occupancy space of the modules is sealed during on-site construction, so that no workmen may enter. The interior of the modules is finished prior to shipment to the construction site, including the installation of all interior service facilities and connecting lines leading from such facilities to a special chamber which is accessible from the exterior of the module. At the construction site workmen can enter this chamber to connect the modules to service risers which extend vertically through a duct formed by vertical alignment of the module chambers, and upper and lower hatchways thereof.

Description

[ 3,750,366 Aug. 7, 1973 United States Patent 91 Rich, 'Jr. et al.

1,083,552 9/1967 Great 52/79 BUILDING [75] Inventors: Frank D. Rich, Jr., Darien;

Primary Examiner-Henry C. Sutherland Attorney- -l-laynes N. Johnson Alexander D. McDonald, Glenbrook, both of Conn.

Assignee: F. D. Rich Housing Corp.,

[57] ABSTRACT A building employing prefabricated room-enclosing Stanford,

Conn.

[22] Filed: July 16, 1971 [21] Appl. No.: 163,274

modules which function also as box-shaped horizontal beams and ties for connecting vertical weightsu ortin columns into a ti id framework. The col- Rehted Apphcamm Data TEES are preferably concre te members which are COllilllllQtlOlhlfl Pfll't 0f Ser. NO. 4,156, Jan. 19, 1970, poured in place into spaces formed between the modaband'medules. The inter-module spaces include vertical chases and horizontal plenums which are in communication with each other and with a heating/cooling plant output, to form an air jacket which surrounds each module over a plurality of its exterior surfaces, and operates as an effective radiant heat exchanger therewith. The heated or cooled air is ultimately discharged into the interior occupancy space of the modules, so as to provide a combination radiant and convective heatinglcooling system. The interior occupancy space of the modules is sealed during on-site construction, so that no workmen may enter. The interior of the modules is finished prior to shipment to the construction site, including the installation of all interior service facilities and connecting lines leading from such facilities to a special chamber which is accessible from the exterior of the module. At the construction site workmen can enter this chamber to connect the modules to service risers which extend vertically through a duct formed by vertical alignment of the module chambers, and upper and lower hatchways thereof.

11 Claims, 22 Drawing Figures Lowe eta1.. 4/1970 Van Hezik..

Rohrer........

France........... 6/1964 Belgium.........

m Ilia SC FFE 0 226 7 656 9 999 l 111 ll/ 6 255 1 6/1910 Conzelman I 2/1914 Donaldson.. 3,514 6/1970 Comm 3,613 10/1971 FOREIGN PATENTS OR APPLICATIONS 042 12/1967 'France...........

n i v i a a PAIENTEU 3.750.366

sum 01 or 13 INVENTORS FRANK D.RICH JR. ALEXANDER D. MCDONALD PATENIEDAUB ms SHEET 02 0 13 INVENTORS FRANK D RICH JR. ALEXANDER D. McDONALD PAIENIEUAUB 1191a sum uu or 13 INVENTORS' FRANKDRICH JR. ALEXANDER D. McDONALD BY 08 mo ATTY.

PAIENIED AUG 7 I973 sum as 0F :3

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PAIENIEU 7W5 3.750.366

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ALEXAN DER D. McDONALD PATENIED 3.750.366

sum U8UF13 INVENTORS FRANK D RICH JR. ALEXANDER D. McDONALD PAIENIED 3,750,366

sum 0s 0F 13 mom m &\ BN N 1: T &9

COM NON 1 3 mom 2 01 Now oom INVENTORS FRANK D. RICH JR. ALEXANDER D. McDONALD PATENTEU 71975 sum 10 or 13 INVENTORS FRANK D. RICH JR. ALEXANDER D. McDONALD PATENTED M19 7 sum .11 0F 13 INVENTORS FRANK D. RICH JR. ALEXANDER D. McDONALD BUILDING CROSS-REFERENCE This application is a continuation-in-part of now abandoned U.S. patent application Ser. No. 4,156 filed Jan. 19, 1970 entitled Improved Building.

FIELD OF THE INVENTION This invention relates generally to construction, and is particularly applicable to high rise apartment buildings employing prefabricated room modules.

BACKGROUND OF THE INVENTION There is a great deal of literature concerning the advantages of prefabricated room-enclosing boxes or modules, and other new techniques such as the use of pou'red-in-place or prefabricated and post-tensioned structural columns to support high rise buildings. It appears, however, that the modular box technique has not yet become standard practice in building construction, and therefore has not been developed to its fullest potential.

Since economics is the key to the adoption of any new construction technique, it appears that the savings presently obtainable by the use of prefabricated room modules are not sufficient. It may be, therefore, that it is necessary for these modules to combine a plurality of functions as a means of achieving still greater construction economies.

Certain problems in particular have been encountered in using prefabricated room modules in high rise buildings. The conventional approach to the construction of multi-story buildings by this method is to stack the modules one upon the other. Thisrequires each module to have sufficient structural strength in the vertical direction to support the weight of all the modules above it. If the modules are identical, for ease of mass production, then they must either be so heavy (to meet the strength requirements of the lower stories) that material is wasted on the upper stories, or they must be so weak as to limit the maximum height of the building. If different types of modules are used for the upper and lower stories, on the other hand, then some of the advantages of mass production are sacrificed, and problems of inventory and storage are intensified.

In order to overcome these difficulties it is necessary to have separate vertical columns which support the weight of the modules on the upper floors. This can be accomplished by means of a conventional structural framework employing vertical columns connected together by horizontal beams and ties, but the erection of such a framework is costly and time-consuming. It has been previously suggested, as in French Pat. No. l,244,983, that the modules can be made to do double duty by functioning as pouring forms, where the columns are made of concrete poured into the interstitial spaces between horizontally spaced modules. Moreover, if the entire space between such modules is not taken up by poured concrete the remaining space can be used for distribution of various service connections throughout the building. This approach is useful, but does not go far enough in extracting all possible economies from the box module concept; and in particular it still requires a complete structural framework. See, for example, U.S. Pat. No. 3,514,910 of Comm.

In construction projects generally, whether or not they employ the box module approach, a persistent problem has been dirtying of the interior room space when workmen enter to perform interior construction and/or finishing work, and to make service connections to on-site facilities such as electricity, water, waste disposal, and fuel. Unavoidably, mud and debris are trackedinto the interior of the new building, necessitating a thorough cleaning operation before the building is ready to receive occupants. This is unavoidable if the interior rooms are constructed on the site; but even with the prefabricated room module approach, as it has been practiced until now, it is necessary to enter the modules to make service connections thereto.

It was recognized some time ago that superior heating and cooling of interior living space could be achieved by conducting heated and cooled air through spaces formed for that purpose in the walls, floors and ceilings. Not only is this expedient suggested in U.S. Pat. No. 2,107,523 of Coe; but it was used in primitive form by the ancient Romans who employed a hypocaust structure, i.e., an under-floor plenum and inwall ducts, to heat their public baths. See Hypocaust, Chambers Encyclopaedia, I959 Edition, Vol. 7, P. 351-52 (published by George Newnes, Ltd., London) for a description of the Roman structure; and for a modern equivalent see Plenum Floor System for Basementless Houses by 0.1. Stout, Better Building Report No. 4, College of Engineering, Pennsylvania State University, University Park, Pa. This approach heats or cools the interior room surfaces, so that the occupants are heated or cooled by radiation. In addition, the heated or cooled air may be conducted into the room interior so that convective heating/cooling effects are superimposed upon the radiative. The individual inwall ducts suggested by Coe, Stout and the Roman architects to achieve this effect, however, are quite laboriously molded into the walls and/or incorporated into the floors by outmoded and uneconomical construction procedures.

THE INVENTION The present invention goes much further in extracting construction economies from the room module approach. It contemplates that the room modules, in addition to enclosing interior space and functioning as molds for poured concrete columns, shall also function as the horizontal structural beams of the building framework. In order to perfonn this function, the modules are connected at opposite ends to the vertical columns, and have sufficient strength in the direction of their longitudinal axes to hold the columns in fixed relationship. In addition, the modules may also have sufficient structural strength in the direction of their transverse horizontal axes to serve as ties, which connect the vertical columns in a second horizontal direction.

In another aspect of the invention, during prefabrication the room modules are completely finished internally and provided with all necessary interior service facilities and connecting lines. Then the doors and windows of the modules are sealed so that no one will enter after the modules are delivered to the construction site. A special service connection chamber is provided, which is accessible from outside the module. All the service lines leading from the interior of the module terminate in this chamber, which the on-site workmen can enter to make connections without entering the living space. In order to form a vertical duct through which service risers can extend through the building,

each of the chambers has upper and lower hatchways, and the chambers and hatchways of each vertical bank of modules are vertically aligned.

In this building, the spaces between horizontally adjacent and vertically adjacent modules contain heated or cooled air, resulting in an advantageous hypocaust type of radiative temperature conditioning system, and also providing convenient channels for conducting the conditioned air into the room interiors for convective as well as radiative heating or cooling. In this respect, the present building is similar to that seen in the Coe patent cited above. According to the present invention, however, the wall chases and the plenums between floors and. ceilings which are required for this type of temperature conditioning system are inherently formed economically and easily by horizontal and vertical spacing apart of the pre-cast room modules as a result of the construction method described herein.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view, with parts broken away for clarity of illustration, of a partially constructed high rise apartment building in accordance with this invention.

FIG. 2 is an end elevational view of a single prefabricated module of the type used in constructing the building of FIG. 1.

FIG. 3 is a fragmentary top plan view of the building of FIG. I, showing the use of bulkheads to segregate a portion of the inter-module space for use as a concrete pouring form for the construction of columns.

FIG. 4 is a fragmentary perspective view showing laterally projecting haunches formed on the poured concrete columns, for the support of the modules immediately above, and the plenum spaces thus defined between modules spaced vertically by the haunches.

FIG. 5 is a fragmentary vertical section of the building of FIG. 1, taken transversely of the modules, and

showing the tapering of module walls and segments of showing decreases in the overall cross-sectional size of each successive column segment as the building progresses upwardly in height.

FIG. 7 is a fragmentary, partially exploded, perspective view, with parts broken away for clarity of illustration, of a pair of outrigger beams'and an exterior gallery to be assembled therewith in the building of FIG. 1.

FIG. 8 is another fragmentary perspective view of an alternative building in accordance with this invention, illustrating the formation of outrigger beams as integral parts of the modules, and showing how these beams support exterior galleries which serve as a common hallway for the various apartment suites in the building.

FIG. 9 is an exploded perspective view, with parts broken away for clarity of illustration, of three separate modules which cooperate with each other to provide the elevator, interior hall, and stairway facilities for the buildings of the preceding figures.

FIG. 10 is a perspective view, with'parts broken away for clarity of illustration, showing the service connection chamber and other features of one of the modules in the buildings represented in the previous figures.

FIG. I1 is a perspective view of the module of FIG. 10, showing the distribution of electrical cables across the top of the module and extending back into the service connection chamber.

FIG. 12 is a fragmentary perspective view of one form of edge junction between upper and lower modules, designed to seal the edges of the plenum spaces formed between vertically spaced modules.

FIG. 13 is a fragmentary perspective view, with parts broken away for clarity of illustration, showing a partition for dividing the plenum space into separate chambers associated with individual apartment suites.

FIGS. 14 and 15 are perspective views of segments of an alternative form of columns for the buildings of the preceding figures, with means for post-tensioning.

FIG. 16 is another perspective view of a similar column segment having an integrally cast outrigger beam for supporting the exterior gallery.

FIG. 17 is a perspective view of an exterior wall panel for use in constructing an end wall for the buildings of the preceding figures.

FIG. 18 is a perspective view of portions of a pair of such wall panels attached to the sides of the modules, and defining a space between the wall panels and the modules, into which concrete may be poured.

FIG. 19 is a perspective view of the T-shaped bulkhead tops which are used to form haunches at the top of each poured concrete column segment.

FIG. 20 is a perspective view of doorway hardware used with communicating rooms of different modules.

FIG. 21 is a nomograph quantitatively analyzing the heating performance of a hypocaust type radiantconvective temperature conditioning system in accordance with this invention.

FIG. 22 is a similar nomograph, but relates to cooling performance.

The same reference numerals designate the same elements throughout the several views of the drawing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A high rise apartment building in accordance with this invention comprises a plurality of individual prefabricated modules 12 arranged in a vertically and horizontally extending formation. These modules serve the basic purpose of enclosing interior room 14. In addition, however, they perform several other functions which are of great importance in deriving the maximum economic benefit from the modular concept; i.e., they constitute the horizontal beams extending across the width of the building (in the direction of the longitudinal axes of the modules) which cooperate with upright supporting columns 16 to form a rigid rectangular framework. Such columns and framework are required for a high rise building.

Such beams do not have the usual I-shaped beam cross-section employed in conventional building construction. The modules I2 are in effect large, hollow box-shaped beams, in which the flanges" are a ceiling plate 18 and a floor plate 22; the webs" are two wall plates 20; and the interior space surrounded by these four plates is the interior living area of the building. In order to develop sufficient longitudinal rigidity and ductility for the modules to function as beams, all four plates are preferably cast of concrete grout material having conventional welded wire reinforcing mesh embedded therein.

work. Note also that the four plates 18, 20 and -22 are r 5 each stiffened by respective integrally cast concrete ribs 52, 40 and 54, which in turn are reinforced by steel rods embedded therein, as for example the rods 41 seen in FIG. 3.

In a preferred embodiment of the invention the box beam modules 12 serve a further function by defining forms in which the vertical columns 16 can be cast by pouring a suitable concrete material into the spaces between horizintally spaced modules. Once the concrete hardens, it forms strong structural members capable of supporting the weight of the upper modules 12. Thus the lower modules are spared the necessity for supporting the weight of the modules above them. Consequently, buildings constructed in accordance with this invention can attain as great a height as any other concrete-frame building, using mass-produced identical modules on each story.

In the process of construction of the illustrated building, first a plurality of poured concrete footings 30 (FIG. 5) are constructed in the ground 32, and a horizontally projecting haunch structure 34 is cast integrally therewith by means of conventional wood pouring forms above ground level. Next, the first level of prefabricated modules 12 is placed upon the haunches 34, which are designed to serve as support pads therefor. In FIG. 5 only one support pad 34 is shown for each module 12, but it will be appreciated that there are at least four such support pads for each module, appearing at the corners thereof. The first level of modules 12.1 and 12.2 are spaced apart laterally as seen in FIG. 5, i.e., in the direction of the width of the modules, leaving a space therebetween into which a first level concrete column segment 16.1 can be poured. As a part of the pouring of segment 16.1, a next level haunch or support pad is formed at thetop of column segment 16.1, by means discussed subsequently. Upon these haunches 34 are placed the second tier of modules 12.3 and 12.4, also in horizontally spaced relation to permit the pouring of a second level concrete column segment 16.2. The latter similarly is integrally cast with a third level set of haunches 34, upon which is erected still another tier of modules 12.5 and 12.6, and the next level poured concrete column segment 16.3. This process is continued through additional tiers of modules such as 12.7 and 12.8, and additional concrete column segments such as 16.4, until the desired number of stories has been erected.

It will be appreciated that the laterally projecting concrete haunch structures 34 are the members which each directly support the weight of the tier of modules 12 immediately above them, but the module weight load is transferred by the haunches 34 to the entire vertical length of column 16 therebelow. As is conventional in' poured concrete construction processes, the individual column segments 16.1 through 16.4, etc. are reinforced by means of the usual steel rods 36 which are put in place before the pouring operation, and ultimately are embedded in the concrete. Usually a length of the rods 36 is allowed to project above each individually poured segment of the columns 16, and is subsequently embedded in the next column segment above, as a means of securing the segments together.

An additional feature of this invention results in a substantial strengthening of the molds, i.e., the module walls 26, without wasting any grout material. When concrete is poured to a substantial depth, as is done here toform the column segments 16.1, 16.2 etc., the hydrostatic pressure exerted on the module walls 20 near the bottom of the mold is considerably greater than it is near the top of the mold. To resist that pressure, the module walls are made thick at the lower region 26A. But that thickness would be unnecessary, and wasteful of material, at the upper region 208; thus the module walls are tapered upwardly as seen in FIG. 5. Consequently each individually poured concrete column segment 16.2, etc. is narrower at its lower region 16A than at its upper region 168. This results in a complementary tapering of the module walls 20 and column segments 16.2 etc., which has advantages in securing the modules 12 and columns 16 together so that they function as a unified building framework. When the weight of the upper stories bears down on the columns 16, a certain amount of compression of the columns takes place. Consequently, the slanted surfaces of each column segment 16.2 etc. wedge downwardly against the complementary slant of the adjacent surfaces of the module walls 20, thus tending to bind the columns 16 and modules 12 together. Moreover, the effective column thickness for load-bearing purposes is that of the poured material 16.2 plus that of the two adjacent module walls 20 to which the poured material 16.2 adheres.

If the total height of the building requires the columns 16 to have maximum load-bearing capacity, the columns can extend along the entire horizontal length of the modules 12; i.e., they can occupy the entire length of the cavity between modules. However, a smaller column cross-section is adequate for an apartment building of ten stories, for example; and considerable concrete material can be saved if the columns 16 are confined to only a portion of the horizontal extent of their inter-module spaces. This is best accomplished, as illustrated in FIG. 3, by inserting expendable bulkheads 42, preferably inexpensive wooden planks, vertically into the space 64 between the side plates 20 of two horizontally spaced modules 12. A convenient way of bracing the wooden bulkhead planks 42 against the hydrostatic pressure of the poured concrete is by placing them against confronting pairs of vertical ribs 66.1 and 410 .3. The entire inter-module space M is thus divided into regions 44.1 and 64.2. The first region 44.1 is the one into which the steel reinforcing rods 36 are inserted, and the material of the concrete columns 16 is poured. The remaining portion .2 of the inter module space remains free of concrete, and thus constitutes a vertical chase which is useful as a vertical distribution conduit for centrally heated or cooled air, or air employed for ventilation.

As seen in FIG. 6, an additional saving of concrete can be achieved by decreasing the width of successive concrete column segments 16.1, 16.2, etc., as the building rises in height, reflecting the fact that each successively higher segment of the concrete columns 16 bears the weight of a smaller number of stories above it. The described decrease in column width on successive floors may be achieved, while using modules with identical rib spacing on each floor of the building, by selecting progressively thicker bulkhead planks 42 to restrict the concrete pour to smaller portions 44.1 of the inter-module spaces 44 as the building increases in height.

During the pouring of each column segment 16.1, 16.2, etc. the required haunch or support pad 34 is formed at the top of the segment within the space defined by the ceiling plates 18 of two adjacent modules such as 12.1 and 12.2 (FIG. 19), special extensions 24.1 formed on the screed ribs 24 of those modules, and T-shaped heads 42.1 formed at the tops of the bulkhead planks 42 to bridge between the screed ribs 24. The haunch pouring form thus defined is filled to a level slightly above the screed rib ex-tensions 24.1 and bulkhead extensions 42.1 (stiff concrete material being used to prevent spillover) so that the haunch 34 becomes the furthest upward projecting, and therefore the weightbearing, member.

The haunches so formed serve not only to support the prefabricated module immediately above, but also serve to space apart each pair of vertically consecutive modules to form a plenum space therebetween. Thus one of the laterally projecting haunches 34 spaces apart a lower level module 12.1 and an upper level module 12.3 immediately above it, so that between the ceiling plate 18 of the lower module and the floor plate 22 of the upper module there is formed a horizontally extending plenum space 50 which is useful for the distribution of air for heating, air-conditioning or ventilating purposes to each of the apartments within the building.

Thus far we have pointed out a number of different functions which are all performed by the modules 12; i.e., they provide interior space enclosures which do not have to be fabricated on the site, they serve as convenient pouring forms for the concrete columns, they form the horizontal structural beams for the building framework, they define various horizontal plenums 50 and vertical chases 44.2, and they ease the problems of designing a high rise building because they are not required to bear the load of all the modules above them. In addition, however, they also serve the further function of tying the columns 16 together in a direction parallel to the transverse horizontal axes of the modules. As seen in FIGS. 1, 4 and 8, each module ceiling plate 18 is formed with exterior stiffening ribs 52, while each module floor plate 22 is formed with exterior stiffening ribs 54. These ribs strengthen the module plates in a transverse direction so that they are able to serve as ties; i.e., structural members which connect the columns 16 in a transverse horizontal direction to complete the rigidity of the structural framework formed by the columns 16 and modules 12.

Thus, as seen in FIG. 8, a given module 12.9 ties together a pair of transversely spaced columns 16.8 and 16.9 to restrain them from moving independently of each other in the horizontal direction. In a conventional building framework the vertical load-bearing columns must not only be connected together in a first horizontal direction by a number of beams, but they must also be connected together in a second horizontal direction by a plurality of ties. The present invention permits a builder to dispense entirely with separate beam and tie members, and to rely only on the modules 12 to perform both functions. Consequently an elaborate cage of beams and ties is entirely replaced by a plurality of modules 12 whose presence is required for space enclosure purposes in any event.

The particular illustrative building embodiment described herein is an apartment house which has an exterior gallery at each floor serving as the common hallway providing access to individual apartment suites. The length of the building extends parallel to the transverse axes of the individual modules 12 and the exterior galleries 60 run along the length of the building, supported by horizontally projecting outrigger beams 62. As seen in FIG. 8, the exterior galleries provide access through main entrance doorways 64 to each apartment suite. These doorways, like the nearby windows 66, are formed in curtain walls 68 made of metal or any other suitable conventional construction material and constructed across the otherwise open end of each module 12 to form the side wall of the building. These curtain walls would normally be installed at the module factory.

FIG. 7 illustrates how the outrigger beams 62 may be separately cast of concrete, embedded in the poured concrete columns 16, and anchored therein by upwardly and downwardly projecting bolts 70, one of which is visible in FIG. 7. Alternatively, the outrigger beams may be formed integrally with the module side walls 20 as illustrated in FIG. 8. In either case the exterior gallery rests upon the outrigger beams, and fits horizontally into mating engagement with a kerf 72 (FIG. 7') formed at the front edge of the floor plate 22 of the module 12 immediately adjacent to each section of the gallery 60. The gallery itself is preferably formed of sections of pre-cast concrete grout, including a floor plate 74 and a safety wall 76 fonned integrally therewith.

Another embodiment of the invention employs prefabricated concrete column segments 16? or (FIGS. 14 and 15) in place of the in situ poured concrete columns 16, or precast concrete column segments 16R (FIG. 16), which are formed with integrally cast outrigger beam extensions 198, in place of the in situ poured concrete beams 16 and the outrigger beams 62 of FIGS. 7 or 8. Such pre-cast beams are conventional in the construction industry, BACKGROUND OF THE INVENTION and are normally formed in onestory lengths or segments, which are then tied together into a complete column structure extending the full height of the building, by means of interlocking depending steel reinforcing rods 201 and upper sockets 203, and the well known post-tensioning technique. For the latter purpose the pre-cast column segments 16?, 16Q and 16R are provided with centrally located hollow liner tubes 200, through which pass posttensioning bars 202 having threaded ends projecting from the top and bottom of the pre-cast segments. As each column segment 161, 160 or 16R is set in place, grout material is poured into the sockets 203 of the lower segment, and the depending rods 201 of the upper segment are inserted thereinto. Then the lower end of the post-tensioning bar 202 thereof is anchored by means of a threaded connection to the upper end of the post-tensioning bar 202 of the column segment immediately below, and then the upper end of the posttensioning bar is pulled tight in an upward direction by means of a jack, and anchored to the top of the column segment by a wedge or any other known means.

In the present building, these pre-cast concrete column segments would have laterally projecting haunches or support pads 34? integrally formed at the bottom of each individual casting 161", 160 or 16R. Then, during the construction of the building, the column segments are the first portion of each building level or story to be put in place; i.e., the segments 161, 160 or 16R for a particular building level are first set in place upon the pre-cast column segments of the level below, after which the modules 12 for the new level are set in place upon the support pads 341 thereof, and the exterior galleries 60 for the new level are put in place upon the integrally cast outrigger beams 198.

The poured-in-place method has the advantage that it inherently joins the columns 16 to the modules 12 so that they are able to perform their function as box beams in the structural framework of the building. In connection with FIG. 5, we have already spoken of the downward wedging action resulting from the complementary slanting surfaces of the module walls 20 and poured concrete column segments 16.2 etc., an effect which can be obtained most easily with the poured-inplace method. In addition, however, each column segment such as 16.3 and its laterally projecting haunches 34, together with the laterally projecting haunches of the column segment 16.2 below it, form a C-shaped pincer formation which grasps the adjacent modules 12.5 and 12.6. Furthermore, the poured concrete material of the columns 16 and haunches 34 tends to adhere to the adjacent concrete grout of the module ceiling plate 18, side plate 20 and floor plate 22. As a result, there is a sufficiently strong connection between each module 12 and the columns 16 located at either end thereof, to connect them into a rigid structural framework in accordance with this invention. In addition, one or more of the vertical reinforcing ribs 40 of each module may be embedded in the poured concrete columns 16, as in the case of the reinforcing ribs 40.2 in FIG. 3, which interlocks the modules and columns to provide additional restraint against the possibility of independent movement.

However, when pre-cast concrete column segments 16?, 16Q and 16R are used, it is not possible to achieve such adhesion, since the concrete column segments and the grout plates of the modules 12 can only come into contact with each other after all have dried and hardened. In addition, it is not possible to form the concrete column segments 161, 160 and 16R about any of the vertical stiffening ribs 40.2 as described above. Accordingly, in order to make a strong column-to-beam connection between the pre-cast column segments and the modules 12, the column segments 16? are provided with horizontally projecting tie rods 204 on opposite sides thereof, and the column segments 16R are each provided with a single such rod 204 on one side thereof (in the latter case opposite the integrally cast outrigger beam 198). As illustrated in FIG. 14, these tie rods are located so that each one of them extends into the hollow of a trough structure 290 projecting upwardly above the juncture of two adjacent modules 12 located adacent to the particular column segment and placed on the floor below. This trough hollow is filled with mortar 292, and after the mortar is allowed to harden, the tie rods 204 are then rigidly connected to the respective modules 12 on the floor below. The opposite ends of the tie rods are embedded in the associated concrete column segment at the time of its casting, so that the modules 12 and column segments are rigidly tied together in accordance with the structural requirements stated above. The details of the trough structure 290 are discussed below in connection with FIG. 13.

The column segment 16R is intended for use on the outside wall of the building, where there are modules on one side only, and therefore no tie rods 204 are required on the opposite side. Instead, the individually cast outrigger beam 198 is required to support the exterior galleries 60. On the opposing outside wall of the building, where there are no exterior galleries, a different type of precast concrete column segment 160 would be used, which has only two tie rods 204, and which lacks the out-trigger beam 198.

An additional feature of construction, of particular importance in zones where earthquakes are a consideration, is a concrete wall (FIG. 8) which extends transversely across the mid-section of one or more modules. As seen in FIG. 9, such an earthquake wall may be formed by pouring liquid concrete between a pair of transverse module walls 82 defining a pouring cavity 84 between them. The resulting earthquake wall 80 is also formed with supporting pads or haunches 34 projecting laterally therefrom, for the purpose of supporting the module 12 immediately above, as in the case of the haunches formed on the column members At one or more points along the length of the apartment building, it is necessary to devote modules on each floor to elevator and stairway facilities, as well as a transverse hallway which provides an elevator waiting area, and preferably also connects with the stair landings. Thus as seen in FIG. 9, on each story of the building are three consecutive modules 12.10, 12.11 and 12.12 which perform these functions. Although shown in an exploded view, it will be understood that these three modules are installed in closely spaced relationship, and are designed to function as a unit. Moreover, each of the three modules illustrated in FIG. 9 has similar modules immediately above and below it in the adjoining stories, with which it cooperate.

Thus, module 12.10 is an elevator shaft module, and is divided into a pair of elevator shaft cubicles and 92, assuming that the apartment building is designed for two elevators. The elevator shaft cubicles 90 and 92 are vertically aligned with similar cubicles in similar modules immediately above and below, thus defining elevator shafts extending vertically through the building. The module 12.10 also includes a superintendents utility room 94 at one end, while at the other end it has a service chamber 96 which is formed with upper and lower hatches 98 and 100 respectively through which various service risers for electricity, plumbing, etc., may extend vertically through the building.

At the sides of elevator shaft cubicles 90 and 92 are formed elevator doorways 102 and 104 respectively, and these are horizontally aligned with elevator doorways 106 and 108 respectively formed in the side of the module 12.11. The entire interior of the latter module forms an interior hallway which is accessible from the exterior gallery 60, so that users of the building pass through it, and enter the'elevators through doorways 106, 102 and 108, 104. In like manner the superintendent's utility closet 94 is formed with an entrance doorway 110 which lines up horizontally with an entrance doorway 112 in the module 12.11, for access from the interior hallway of the module 111.

Reference numeral 12.12 designates a stairway module having landing areas 114 and 116 at the opposite ends thereof, and two staircases 118 between the landings. The staircases 118 of each module 12.12 are in scissors relationship, and connect the landing area 114 of one module with the landing area 116 of another module. Stacking the modules 12.12 in a vertical bank thus produces a continuous double stairway extending vertically through the building, just as stacking the elevator shaft modules 12.10 produces a pair of continuous elevator shafts. Doorways 120 and 122 are formed in the modules 12.11 and 12.12 to permit passage from the interior hall to the stair landing 114, while a similar pair of doorways 124 and 126 connects the hallways with stair landing 116.

Wherever two adjacent modules are required to have interconnecting doorways, as the cooperating modules do in FIG. 9, or as would be true of a relatively large apartment suite extends over more than one module, there must be a certain tolerance for both horizontal and vertical misalignment of confronting doorway openings, due to unavoidable errors in the placement of modules. Among several solutions to the horizontal misalignment problem, perhaps the simplest is to make the one of the doorways in which the door is installed (e.g., doorway 122 in FIG. 9) smaller in the horizontal direction that its cooperating doorway 120. If the size difference is made equal to twice the largest expected horizontal misalignment, then even in the event of a maximum horizontal offset in either direction, the smaller doorway 122 will not be displaced beyond the alignment field of the larger doorway 120. Thus functional alignment will always be possible, as long as tolerance limits are not exceeded. Of course the two different-sized doorways can not meet precisely at both edges of the doorway, and may not meet at either edge, depending on the exact positioning of the modules; but this is an esthetic rather than a functional problem. For sealing purposes there are confronting hoods 123 and 125 entirely surrounding the cooperating doorways 120 and 122 respectively on all four sides, and these hoods project into close proximity with each other but do not touch. See FIGS. 9 and 20. Sealing contact is made by an elastomeric gasket 127 previously installed within a suitable recess formed in one of the confronting hood surfaces, for example hood 125.

The extent of vertical misalignment is expected to be fairly small; but nevertheless, in order to prevent tripping, and to cover over the small gap between hoods 123 and 125 at the bottom of the doorway, there is provided a walkover plate 250 (FIG. which is bolted to a plurality of attachment clips 252. These clips grip a flange 251 at the lower edge of doorway hood 123. The clips 252 may be released or tightened against the flange by means of bolts 254, which also serve to fasten the plate 250 to the clips. When the bolts 254 are sufficiently loosened, the clips 252 are released so that the clips and the plate 250 can be advanced toward or retracted from the hood 125, by sliding horizontally over the lower edge flange 251. Initially these plates are in a retracted position so as not to interfere with placement of the modules. But after placement has been accomplished, the modules are entered for the purpose of advancing the walkover plates 250 into bridging position. Then they are finally secured in place.

If the inevitable horizontal mismatch between different sized doorways is considered esthetically objectionable, the adjustable type of doorframe hardware illustrated in FIG. 20 may be employed to cover up. This includes a door buck 260 which is secured by clips 262 to flanges 266 formed on both sides of doorway hood 123. These clips are secured by bolts 264, which also serve to attach the buck 260 to the clips 262. In similar fashion, door jambs 270 are secured by clips 272 and bolts 274 to flanges 275 on both sides of the cooperating doorway hood 125. After releasing the bolts 274 sufficiently, the jambs 270 can be adjusted horizontally relative to the flanges 276 to line up the jambs with the adjacent section of the buck 260, and then the bolts 274 are tightened. A cover plate 278 is secured to each jamb 270 and is adjustable horizontally relative thereto by means of bolts 282 and elongated slots 280, to more into abutment with the adjacent section of the door buck 260. The adjustment of the jambs 270 and cover plates 278, like the adjustment of the walkover plate 250, is accomplished from inside the modules, after they have been set in place.

In accordance with an additional aspect of this invention, the curtain walls 68 are installed and the doorways 64 leading to the interior of each module are sealed at the factory where the module is manufactured, thus preventing workmen from entering the module interiors after delivery to the construction site. Another doorway 134, seen in FIGS. 10 and 12, leads into a special chamber 136 which is completely partioned off from the remainder of the module 12; i.e., there is no access from the chamber 136 to those rooms of the module which are intended for human use or occupancy. Within the latter rooms are various service facilities such as electrical outlets, gas lines if a gas stove is installed, plumbing fixtures for the delivery of hot and cold running water and for waste diSposal and suitable openings for the delivery of air for heating, air conditioning or ventilation purposes, and/or hot water radiators for heating purposes if that type of heating system is employed. From each of these facilities, factoryinstalled service lines 141 of the appropriate type, e.g., and electrical cable, a hot or cold water pipe, a waste disposal pipe, a vent line, a gas pipe, etc., lead through the interior of the module and ultimately reach the chamber 136 for connection to heating and/or airconditioning unit (if each suite has its own unit), and/or to service risers 142 within the chamber. The unit 140 can be a hot water heater which supplies hot water for washing as well as for space heating purposes if the latter type of heating system is employed, and/or a unit which provides heat for a hot air heating system and/or an air-conditioning unit which provides cold air during the summer months. The risers 142 would ordinarily include a cold water supply, waste drain, vent, electrical supply, and a gas or oil fuel supply, if required for the kitchen stove or heater 140. These service risers 142 are field-installed in the chamber 136, and a can be connected to the heater/air-conditioner unit 140, as well as to all the service lines 141, by entering the chamber 136. Consequently, no workmen are required to enter the other rooms of the module 12.13. This has the advantage of keeping those rooms in factory-clean condition during the on-site phase of construction. The first person to enter the other rooms of the module 12 is the first occupant of the apartment suite; yet he finds complete electrical, plumbing, heating and air-conditioning facilities completely connected and in operating condition on his arrival.

If anapartment suite extends over more than one module, and if the hardware of FIG. 20 is employed at

Claims (11)

1. A multi-story building of modular construction including a plurality of modular box beams of substantially similar structural strength, each said beam enclosing at least one room of the interior space of said building, said box beams being in spaced horizontal layers and in spaced vertical alignment, a plurality of vertical columns for supporting the weight of said box beams, said columns being cast-in-situ in laterally and longitudinally spaced apart relation and being positioned between said horizontally spaced box beams adjacent the ends thereof box beam support members on said columns to receive and support the box beams of the story thereabove, said box beams being rigidly bonded to said support members, and said box beams above the ground floor being supported substantially entirely upon said support members and having strength enough to span the space between said support members without support from box beams therebelow, whereby said box beams have substantially their entire weight carried by said vertical columns.

2. A multi-story building as set forth in claim 1 in which said box beams collectively bear at least the major portion of all horizontal structural loads of said building in the direction of the longitudinal axes of said box beams.

3. A multi-modular building adapted for ready on-site construction through use of pre-fabricated modules of uniform strength, said building including: a base support, a plurality of layers of box beam room modules, each of said layers including a plurality of said room modules in spaced horizontal relationship, said layers being positioned one above another with said room modules in spaced vertical alignment, a series of vertical concrete supporting columns fabricated of material in a portion of the space between said horizontally disposed modules, said columns being spaced apart laterally and longitudinally of said modules and positioned near the ends thereof, said supporting columns carrying module supporting shoulders for said layers of modules above said base, said cast-in-situ supporting shoulders and columns bearing the weight of the respective modules positioned thereabove and rigidly binding horizontally adjacent modules together, said room modules having sufficient structural strength to be self-supporting between said shoulders, whereby a building is constructed of substantially uniform room modules which do not themselves support the weight of the modules thereabove.

4. A building as in claim 3 wherein: said box beams have side walls reinforced with a plurality of exterior vertical ribs, at least some of said ribs of confronting box beam walls engaging with said cast in situ columns to provide structural rigidity.

5. A building as in claim 3 wherein: the width of said columns decreases with increasing height of said building.

6. A building as in claim 3 wherein: said box beams comprise side plates formed with a downwardly increasing tHickness, and the confronting outer surfaces of said side plates of horizontally consecutive box beams converge toward each other in the downward direction, whereby said columns cast-in-situ therebetween taper downwardly to a smaller thickness at the lower portion of each story than at the upper portion thereof.

7. A building as in claim 3 wherein: horizontal outrigger beams are embedded in said poured columns and project beyond said box beams, and an external gallery is supported upon said outrigger beams.

8. A building as in claim 3 wherein: said box beams have side walls reinforced with exterior vertical ribs, and said cast in situ column material interlocks said box beams and columns against mutual displacement along the longitudinal axis of said box beams.

9. A building as in claim 1 wherein: said room-enclosing box beams also extend between two of said columns in a second horizontal direction transverse to the longitudinal axis of said box beams, and are secured thereto and effective to act as horizontal ties between said columns for lending horizontal rigidity to said framework along said second horizontal direction; and said room-enclosing box beams collectively also bear at least the major portion of all structural loads exerted by said building in said second horizontal direction.

10. A building as in claim 9 wherein said structural framework includes no other horizontal structural members apart from said room-enclosing boxes which are capable by themselves of bearing the horizontal structural loads exerted by said building.

11. A building as in claim 10 wherein said structural framework consists exclusively of said columns and said room-enclosing boxes.

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