Interchangable modular construction method
View Patent ↗A modular building at a job site comprises one or more volumes templates, each comprising two or more core locations and a corridor all bounded within a volume footprint. A core for each core location is selected from a core catalog. Each core includes a base, at least three walls projecting upward from a floor of the base, a ceiling closing off an interior space, and an interior kit of internal walls, appliances, fixtures, and the like. Each volume template, the selected cores, and internal kits are constructed concurrently at a manufacturing facility along with external walls to complete each volume, which is transported to the job site. Adjacent volumes are connected together, with service lines of each core being connected with supply lines at the job site.
1. A method for fabricating a building on a job site support surface having two or more supply lines, comprising the steps:
defining a core library of two or more cores, each core comprising:
a base having a perimeter, a lower side adapted for resting on the job site support surface, and an upper side adapted for supporting a floor;
three or more core walls projecting upward from the floor about the perimeter of the base and defining an interior space, each core wall including an inner side and an outer side, at least one of the core walls being a service wall enclosing two or more service lines;
a ceiling closing the interior space above the core walls;
a plurality of internal kits, each comprising a plurality of internal elements taken from the set of walls, appliances, cabinets, fixtures, windows, and doors, and each internal kit having an associated bill-of-materials comprising the internal elements;
adding at least one shear panel to the inner side of the service wall of each core;
providing direct access to the service lines of one of the cores from the corridor;
defining two or more volume templates each including one or more core locations and a corridor, each core location being adapted to receive any of the cores in the core library within;
defining at least two exterior walls per volume, the at least two exterior walls designated as part of either the volume template or the one or more cores bound within the volume template, each exterior wall having an exterior surface and an interior surface; and
defining a plurality of stitch plates for mutually fixing the volumes together on the job site support surface at attachment zones of the exterior walls;
selecting one or more of the volume templates that together define an exterior perimeter of the building;
selecting for each volume template two or more of the cores and internal kits;
obtaining building materials for the volume templates, cores, and internal kits;
constructing the volume templates and cores bound within the volume templates concurrently and adding the internal elements of the selected internal kits to complete a volume;
transporting each completed volume to the job site support surface; and
assembling the volumes together on the job site support surface, connecting adjacent volumes together with at least one stitch plate at the pre-defined attachment zones of the volumes, and connecting the service lines of each core with the supply lines.
2. The method of claim 1 further including the step:
providing for each core of each volume template either a doorway into the corridor or a walkway into an adjacent core in an adjacent volume template.
3. A building obtained by the method for fabricating a building of claim 2 .
4. The method of claim 1 further including the steps:
providing a stairwell with at least two of the cores, and providing multiple levels of cores, each stairwell providing access from the corridor of each level with the corridor of a next upper level and a next lower level; and
connecting the service lines of each core with the service lines of a next upper core and/or a next lower core.
5. A building obtained by the method for fabricating a building of claim 4 .
6. A building obtained by the method for fabricating a building of claim 1 .
7. A building for a job site support surface having two or more supply lines, comprising:
one or more volume templates, each volume template comprising one or more core locations and a corridor all bounded within in a volume footprint, the one or more volume templates together defining an exterior perimeter of the building;
a core for each core location of each volume template, each core selected from a core library having a plurality of available cores that each include:
a base having a perimeter, a lower side adapted for resting on the job site support surface, and an upper side adapted for supporting a floor;
three or more core walls projecting upward from the floor about the perimeter of the base and defining an interior space, each core wall including an inner side and an outer side, at least one of the core walls being a service wall enclosing two or more service lines;
a ceiling closing the interior space above the core walls; and
a plurality of internal kits, each comprising a plurality of internal elements taken from the set of walls, appliances, cabinets, fixtures, windows, and doors, and each internal kit having an associated bill-of-materials comprising the internal elements and required building materials therefore;
at least two exterior walls designated as part of either the volume template or the one or more cores bound within the volume template, each exterior wall having an exterior surface and an interior surface; and
a plurality of stitch plates for mutually fixing the volumes together on the job site support surface at attachment zones of the exterior walls;
wherein each volume template, the selected cores, and internal kits are constructed concurrently with the building materials to form a completed volume, each completed volume transported to the job site support surface, adjacent volumes being connected together with at least one of the stitch plates at the pre-defined attachment zones of the external walls, service lines of each core being connected with the supply lines;
wherein the service wall includes at least one shear panel fixed with the inner side thereof; and
wherein the service lines of the service wall of each core are accessible from the corridor outside of the interior space and the shear wall of the core.
8. The building of claim 7 wherein at least one of the core walls includes at least one shear panel fixed with the inner side thereof.
9. The building of claim 7 wherein each core of each volume includes either a doorway into the corridor or a walkway into an adjacent core of an adjacent volume.
10. The building of claim 7 including multiple levels of cores, at least one of the cores in one of the volumes on each level including a stairwell, the stairwell providing access from the corridor of each level with the corridor of a next upper level and a next lower level, the service lines of each core being connected with the service lines of a next upper core and/or a next lower core.
11. A building for a job site support surface having two or more supply lines, comprising:
one or more volume templates, each volume template comprising one or more core locations and a corridor all bounded within in a volume footprint, the one or more volume templates together defining an exterior perimeter of the building;
a core for each core location of each volume template, each core selected from a core library having a plurality of available cores that each include:
a base having a perimeter, a lower side adapted for resting on the job site support surface, and an upper side adapted for supporting a floor;
three or more core walls projecting upward from the floor about the perimeter of the base and defining an interior space, each core wall including an inner side and an outer side, at least one of the core walls being a service wall enclosing two or more service lines;
a ceiling closing the interior space above the core walls;
at least one shear panel fixed with the inner side of the service wall, wherein the service lines of the service wall of each core are accessible from the corridor outside of the interior space and the shear wall of the core; and
a plurality of internal kits, each comprising a plurality of internal elements taken from the set of walls, appliances, cabinets, fixtures, windows, and doors, and each internal kit having an associated bill-of-materials comprising the internal elements and required building materials therefore;
wherein each volume template, the selected cores, and internal kits are constructed concurrently with the building materials to form a completed volume, each completed volume transported to the job site support surface.
12. The building of claim 11 wherein each core of each volume includes either a doorway into the corridor or a walkway into an adjacent core of an adjacent volume.
13. The building of claim 11 including multiple levels of cores, at least one of the cores in one of the volumes on each level including a stairwell, the stairwell providing access from the corridor of each level with the corridor of a next upper level and a next lower level, the service lines of each core being connected with the service lines of a next upper core and/or a next lower core.