Prefabricated deck, wall, and roof systems
A prefabricated modular building system includes any of a deck, wall panel, and roof panel, each of which can, but need not always, include an ultra-high-performance concrete portion bonded to a foam portion to form a composite. The deck includes connection points for attachment of a stabilization structure and for releasable attachment of transport components such as a hitch and axle assemblies. The deck is fabricated off-site, and transportable to a delivery site where the transport components can be detached and the deck is placed on a foundation or piers. The stabilization structure can, in some implementations, form a complete building.
1 . A prefabricated structure comprising:
a deck configured to form a vehicle trailer chassis, the deck comprising:
a frame;
a foam portion positioned within the frame and a concrete portion at least partially covering the foam portion;
one or more channels defined in the foam portion having at least one utility conduit positioned therein;
one or more reinforcement components embedded in the concrete portion; and
one or more connection points connected to the frame and protruding outwardly from the concrete portion, the concrete portion at least partially covering the one or more connection points;
an axle assembly removably coupled to a first said connection point disposed on a bottom side of the deck and configured to transport the deck to a delivery location; and
a hitch removably coupled to a second said connection point disposed on a front side of the deck and configured to transport the deck via the hitch.
2 . The prefabricated structure of claim 1 , wherein the concrete portion of the deck comprises an ultra-high-performance concrete.
3 . The prefabricated structure of claim 1 , wherein the at least one utility conduit positioned within the one or more channels includes integrated utility conduits for connection to site utilities.
4 . The prefabricated structure of claim 1 , wherein the deck is a first deck, the first deck configured to couple to a second deck at the delivery location, wherein the first deck and the second deck are coupled in a single-floor orientation.
5 . The prefabricated structure of claim 1 , wherein the deck is configured as a portion of a multi-story building assembled at the delivery location.
6 . The prefabricated structure of claim 1 , wherein the deck is transported to the delivery location on the axle assembly.
7 . The prefabricated structure of claim 6 , wherein the hitch is configured to engage a vehicle to transport the deck via the hitch to the delivery location.
8 . The prefabricated structure of claim 7 , wherein the deck forms the vehicle trailer chassis.
9 . The prefabricated structure of claim 1 , further comprising a stabilization structure comprising at least one wall panel, wherein the at least one wall panel is coupled to a third connection point of the deck.
10 . The prefabricated structure of claim 9 , wherein the stabilization structure comprises a plurality of wall panels defining a room therebetween, and at least one roof panel coupled to the plurality of wall panels, such that the stabilization structure forms a building.
11 . The prefabricated structure of claim 10 , wherein the deck is a first deck, the first deck configured to couple to a second deck at the delivery location, wherein the first deck and the second deck are coupled in a single-floor orientation.
12 . The prefabricated structure of claim 10 , wherein the deck is configured to form, at the delivery location, a portion of a multi-story building.
13 . The prefabricated structure of claim 10 , wherein the building comprises a house.
14 . The prefabricated structure of claim 13 , wherein the house comprises a wall panel and a roof panel, wherein at least one of the wall panel or the roof panel comprises ultra-high-performance concrete, and wherein the foam portion of the deck provides thermal insulation for a bottom side of the house.
15 . The prefabricated structure of claim 9 , wherein the stabilization structure further comprises at least one roof panel coupled to the at least one wall panel, wherein the at least one wall panel or the at least one roof panel comprises ultra-high-performance concrete.
16 . The prefabricated structure of claim 15 , wherein the at least one of the roof panel and the at least one wall panel comprise an opening defined therethrough.
17 . The prefabricated structure of claim 16 , wherein the opening defined in the at least one roof panel or the at least one wall panel is configured for a door or a window to be coupled thereto.