HURRICANE RESISTANT PRECAST CONCRETE HOMES

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]The present application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 63/742,221, filed Jan. 6, 2025, entitled HURRICANE RESISTANT PRECAST CONCRETE HOMES, which is incorporated herein by reference in the entirety.

TECHNICAL FIELD

[0002]The present disclosure relates generally to construction and, more particularly, construction of precast homes.

BACKGROUND

[0003]In many locations, houses may be subject to extreme natural forces at various times of the year. These include, but are not limited to, hurricanes, tornadoes, and flooding. High speed wind forces, combined with heavy rain can also cause objects to fall on buildings and power lines, creating fire hazards, especially to wood framed homes. Currently, homes are typically built with wooden frames and other low strength materials. These homes may not survive the speed of winds, the flooding, and the burning associated with such natural forces which may lead to a complete or partial destruction of the home. Additionally, storms, such as hurricanes, may bring storm surges, which may result in flooding for extended periods of time, particularly of low-lying homes, and homes near bodies of water. Such high-tide water can cause permanent damage and health hazards to the occupants and may render the house damaged beyond repair.

[0004]Therefore, there exists a need for homes that cure one or more of the shortfalls of previous construction materials and systems as identified above.

SUMMARY

[0005]A module is disclosed, in accordance with one or more embodiments of the present disclosure. In embodiments, the module includes a platform. In embodiments, the platform includes a skin. In embodiments, the platform includes a perimeter. In embodiments, the platform includes a plurality of ribs, wherein the ribs are disposed under the skin of the platform and surrounded by the perimeter of the platform. In embodiments, the module includes three or more columns, wherein each of the three or more columns are coupled to the platform. In embodiments, the module includes a reinforcement assembly to couple each of the three or more columns to the platform. In embodiments, the reinforcement assembly includes a sleeve placed within a channel in each of the three or more column and the platform. In embodiments, the reinforcement assembly includes a reinforcement member placed within the sleeve. In embodiments, the reinforcement assembly includes a filling, wherein the filling is configured to fill the channel and the sleeve and surround the reinforcement member or order to couple each of the three or more columns to the platform.

[0006]An assembly is disclosed, in accordance with one or more embodiments of the present disclosure. In embodiments, the assembly includes two or more modules coupled to each other. In embodiments, each module includes a platform. In embodiments, the platform includes a skin. In embodiments, the platform includes a perimeter. In embodiments, the platform includes a plurality of ribs, wherein the ribs are disposed under the skin of the platform and surrounded by the perimeter of the platform. In embodiments, each module includes three or more columns, wherein each of the three or more columns are coupled to the platform. In embodiments, each module includes a reinforcement assembly to couple each of the three or more columns to the platform. In embodiments, the reinforcement assembly includes a sleeve placed within a channel in each of the three or more column and the platform. In embodiments, the reinforcement assembly includes a reinforcement member placed within the sleeve. In embodiments, the reinforcement assembly includes a filling, wherein the filling is configured to fill the channel and the sleeve and surround the reinforcement member or order to couple each of the three or more columns to the platform.

[0007]A module is disclosed, in accordance with one or more embodiments of the present disclosure. In embodiments, the module includes two inverted T beams. In embodiments, each of the two inverted T beams includes a central portion. In embodiments, each of the two inverted T beams includes two side portions flanking the central portion, wherein the central portion is thicker than the two side portions to define a ridge on either side of the two inverted T beams, wherein the two side portions extend beyond the central portion to define a cavity on either end of the two inverted T beams. In embodiments, the module includes two rectangular beams running parallel to each other and intersecting the two inverted T beams. In embodiments, each of the two rectangular beams includes notches in at least two corners of each of the two rectangular beams. In embodiments, each of the two rectangular beams includes one or more rods extending into each of the notches. In embodiments, the module includes four columns configured to vertically support the two inverted T beams and the two rectangular beams, wherein the cavity of each of the two inverted T beams partially surrounds the four columns. In embodiments, each of the four columns includes. In embodiments, each of the four columns includes one or more corbels to support the two inverted T beams and the two rectangular beams. In embodiments, each of the four columns includes one or more dowel bars extending out of the one or more corbels, wherein the dowel bars are inserted into dowel holes in the two inverted T beams and the two rectangular beams. In embodiments, each of the four columns includes one or more rod sleeves to receive the one or more rods from the two rectangular beams. In embodiments, the module includes a binding material filling the notches of the two rectangular beams, the cavity of each of the two inverted T beams, and the one or more rod sleeves of the four columns. In embodiments, the module includes a slab, wherein the slab rests on the ridge 410 of the two inverted T beams and is bounded by the central portion of the two inverted T beams and the two rectangular beams. In embodiments, the module includes a concrete topping over the slab.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]The detailed description is given with reference to the accompanying figures. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items. Various embodiments or examples (“examples”) of the present disclosure are disclosed in the following detailed description and the accompanying drawings. The drawings are not necessarily to scale. In general, operations of disclosed processes may be performed in an arbitrary order, unless otherwise provided in the claims.

[0009]FIG. 1A illustrates a three-dimensional (3D) view of a module, in accordance with one or more embodiments of the present disclosure.

[0010]FIG. 1B illustrates a cross-sectional side view of a module, in accordance with one or more embodiments of the present disclosure.

[0011]FIG. 1C illustrates a cross-sectional side view of a module, in accordance with one or more embodiments of the present disclosure.

[0012]FIG. 1D illustrates possible dimensions of a platform of the module, in accordance with one or more embodiments of the present disclosure.

[0013]FIG. 2A illustrates a top view of an assembly of two modules coupled to each other, in accordance with one or more embodiments of the present disclosure.

[0014]FIG. 2B illustrates a top view of an assembly of two modules coupled to each other, in accordance with one or more embodiments of the present disclosure.

[0015]FIG. 2C illustrates an end cross-sectional view of two modules coupled to each other, in accordance with one or more embodiments of the present disclosure.

[0016]FIG. 2D illustrates an end cross-sectional view of two modules coupled to each other, in accordance with one or more embodiments of the present disclosure.

[0017]FIG. 2E illustrates a cross-sectional side view of a coupling between two modules, in accordance with one or more embodiments of the present disclosure.

[0018]FIG. 2F illustrates a cross-sectional side view of a coupling between two modules, in accordance with one or more embodiments of the present disclosure.

[0019]FIG. 2G illustrates a perspective view of two modules coupled to each other, in accordance with one or more embodiments of the present disclosure.

[0020]FIG. 2H illustrates perspective view of modules coupled to each other and stacked in accordance with one or more embodiments of the present disclosure.

[0021]FIG. 3 illustrates a perspective view of a module where the platform is formed from two pieces, in accordance with one or more embodiments of the present disclosure.

[0022]FIG. 4A illustrates components of a module where the platform is formed from multiple pieces, in accordance with one or more embodiments of the present disclosure.

[0023]FIG. 4B illustrates an assembly created using the modules illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0024]FIG. 4C illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0025]FIG. 4D illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0026]FIG. 4E illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0027]FIG. 4F illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0028]FIG. 4G illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0029]FIG. 4H illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0030]FIG. 4I illustrates a step of assembly the module illustrated in FIG. 4A, in accordance with one or more embodiments of the present disclosure.

[0031]FIG. 5 illustrates possible columns of the module, in accordance with one or more embodiments of the present disclosure.

[0032]FIG. 6A illustrates connections between the columns and the platform of the module, in accordance with one or more embodiments of the present disclosure.

[0033]FIG. 6B illustrates connections between the columns and the platform of the module, in accordance with one or more embodiments of the present disclosure.

[0034]FIG. 6C illustrates connections between the columns and the platform of the module, in accordance with one or more embodiments of the present disclosure.

[0035]FIG. 7A illustrates connections between the columns of the module and a footing, in accordance with one or more embodiments of the present disclosure.

[0036]FIG. 7B illustrates connections between the columns of the module and a footing, in accordance with one or more embodiments of the present disclosure.

[0037]FIG. 8A illustrates a cross-sectional side view of a coupling between two modules, in accordance with one or more embodiments of the present disclosure.

[0038]FIG. 8B illustrates a cross-sectional side view of a coupling between two modules, in accordance with one or more embodiments of the present disclosure.

[0039]FIG. 9 illustrates connection of flooring to the platform of a module, in accordance with one or more embodiments of the present disclosure.

[0040]FIG. 10A illustrates a concrete roof, in accordance with one or more embodiments of the present disclosure.

[0041]FIG. 10B illustrates a concrete roof, in accordance with one or more embodiments of the present disclosure.

[0042]FIG. 11A illustrates a wall panel, in accordance with one or more embodiments of the present disclosure.

[0043]FIG. 11B illustrates a wall panel, in accordance with one or more embodiments of the present disclosure.

[0044]FIG. 12A illustrates an assembly of modules in a coastal area, in accordance with one or more embodiments of the present disclosure.

[0045]FIG. 12B illustrates an assembly of modules in a coastal area, in accordance with one or more embodiments of the present disclosure.

[0046]FIG. 12C illustrates floor layout for the assembly of modules in a coastal area, in accordance with one or more embodiments of the present disclosure.

[0047]FIG. 13 illustrates an assembly of modules in a midwestern region of the United States, in accordance with one or more embodiments of the present disclosure.

[0048]FIG. 14 illustrates an example of an assembly of modular housing, in accordance with one or more embodiments of the present disclosure.

[0049]FIG. 15 illustrates a flow diagram depicting a method, in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

[0050]Before explaining one or more embodiments of the disclosure in detail, it is to be understood that the embodiments are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. In the following detailed description of embodiments, numerous specific details may be set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art having the benefit of the instant disclosure that the embodiments disclosed herein may be practiced without some of these specific details. In other instances, well-known features may not be described in detail to avoid unnecessarily complicating the instant disclosure.

[0051]Embodiments of the present disclosure are directed to a module. The module may be formed largely from high strength remotely prefabricated concrete. The module may be constructed from one or more modules. Each module may include a platform (e.g., a table) and columns to support the platform. Various components of the module may be produced in a factory as precast concrete columns and platforms and then shipped to jobsites. This may provide fast erection of homes (e.g., three or fewer days) and reduce the amount of work that is required to be performed at a jobsite during construction, such as eliminating the need for jobsite forming (e.g., cast-in-place concrete framing systems) and the need for certified jobsite welding.

[0052]Multiple housing modules may be combined to form a complete framework for a structure (e.g. a home) or an assembly. As an example, any number of modules may be placed next to each other (e.g., width to width, length to length, or length to width) or on top of each other to create a layout as desired by the customer. It is contemplated that in certain localities (e.g., coastal localities) it may be required to have the bottom 8 to 12 feet above ground, be free of load-bearing walls, and to be limited to non-living space (e.g., only parking and storage) to protect people against flooding and to reduce damage to the part of the structure that would be flooded in a flood surge.

[0053]Such a strong precast concrete open load-bearing and column-supported module, as described herein, may provide many benefits over traditional load-bearing wall supported construction techniques. For example, the module may be highly modular and customizable, thus providing solutions for coastal areas that experience hurricanes and flooding and midwestern areas that experience tornadoes. By way of another example, the module may be resistant to hurricanes, tornados, wind, flooding, and fire. As such, the module may be capable of withstanding wind speeds of at least 180 miles per hour (mph), even in constructions where the first floor is open and formed only with columns. Additionally, the module may withstand at least 12 feet of flood surge without the need to depend on load bearing walls at ground level. By way of another example, the module may be used to build above existing single-story homes in order to enhance protection. By way of another example, while the module may provide the structural considerations necessary to protect against natural forces, other facets of the home (e.g., the interior, the exterior, and the roof) may be highly customizable and constructed to resemble normal housing.

[0054]FIG. 1A illustrates a three-dimensional view of a precast concrete framing module 100, in accordance with one or more embodiments of the present disclosure. FIGS. 1B and 1C illustrate cross-sectional views of the module 100, in accordance with one or more embodiments of the present disclosure.

[0055]In embodiments, the module 100 includes a platform 102. The platform 102 may include a skin 104, ribs 106 disposed under the skin 104, a perimeter 108, and spaces 110. The platform 102 and all of its components (e.g., skin 104, ribs 106, and perimeter 108) may be made from high strength concrete. Additionally, the platform 102 may be precast out of the high strength concrete. As such, the skin 104, ribs 106, and perimeter 108 may be made from a single, monolithic material. However, it is noted that the platform 102 may not be formed as a single piece of precast monolithic concrete, and may instead be formed from several discreet pieces.

[0056]The skin 104 of the platform 102 may be a thin layer that sits atop of the ribs 106. As such, the skin 104 may provide the surface of the platform which will be used as a floor, or other flat surface to support weight.

[0057]The ribs 106 of the platform may sit under the skin 104. The ribs may run across a width of the platform 102 and span the length of the platform 102, or a partial length of the platform 102. The ribs 106 may be evenly spaced across the platform 102. The ribs 106 may run parallel to each other and/or one edge of the platform. The ribs 106 may be configured to add support to the skin 104 such that the platform 102 may be capable of holding weight significantly higher than the weight the skin 104 would be otherwise capable of holding. However, the ribs 106 may be preferred to a solid platform 102 because the provide for a balance of weight and strength.

[0058]The platform 102 may include a perimeter 108. The perimeter 108 may trace the edges of the platform 102. The perimeter 108 may be configured such that the ribs 106 extend between the perimeter on either side of the platform 102.

[0059]The perimeter 108 and ribs 106 may define spaces 110 in the platform 102. The spaces 110 may be areas where there is no concrete, and only air. As such, the spaces 110 may allow for a reduced weight for the platform 102.

[0060]In embodiments, the module 100 includes columns 112. The columns 112 may be coupled to the platform 102 in order to lift the platform above the ground and/or above additional modules 100. The module 100 may include any number of columns 112 coupled to the platform 102 at any location. For example, the module 100 may include four columns 112 with one column 112 located at each corner of the platform 102. By way of another example, the module 100 may include 6 columns 112, with four columns 112 located at each corner of the platform 102 and two additional columns 112 located on either side of the center of the platform 102.

[0061]The columns 112 may be any shape. For example, the columns 112 may be rectangular, circular, T shaped, or L shaped. Additionally, each module 100 may include any combination of column shapes. It may be preferred to locate L shaped columns 112 at the corners of the platform 102, T shaped columns at the edges of the platforms 102, and rectangular shaped columns 112 at the center of the platform 102.

[0062]FIG. 1D illustrates possible dimension of a platform 102 of the module 100, in accordance with one or more embodiments of the present disclosure.

[0063]It should be noted that the length and width of the platform 102 may be any size. However, size may be limited by other considerations, such as weight and width of a single piece of platform 102, width restrictions on roads, building restrictions, or the like. As a result, it may be desirable to prescribe a width for the platform to be between 6 and 14 feet, with options in two-foot increments. Additionally, the total length of the platform may be characterized by the equation L=2A+NB, where A is the size of the perimeter 108, B is the distance between the center of two ribs 106 (e.g., 4 feet), and N is the number of ribs 106 on the platform. It is contemplated that it may be desirable to have a length between 8 and 72 feet, with a number of ribs 106 between 1 and 17.

[0064]The width of the platform 102 may vary according to the application. The platform 102 may not be expected to be wider than 12 feet. The limited width may allow for trucks to haul the platform 102 in a flat position without exceeding the width of a standard traffic lane. In some states, however, platforms 102 as wide as 14 feet can still be hauled with minimal cost premium. The length of the platform 102 can vary from twice the width to about 70 feet. The weight of the platform 102 can be as much as 50,000 pounds with reasonable hauling costs, and even heavier for additional hauling and erection costs. The platform 102 may include the perimeter 108 and the interior skin 104 and ribs 106, all of which may be poured monolithically in a precasting facility. The spacing between ribs may be kept constant within each platform 102 but can vary between 3 and 5 feet, depending on platform 102 length and skin 104 thickness. The skin 104 thickness may be kept at a minimum of 2.5 inches to allow for one cage of orthogonal rebars to be inserted into the platform 102, with adequate cover for corrosion resistance. A minimum of four columns may support the platform 102 at the four corners of the platform 102. However, it is noted that under certain circumstances, three columns may provide adequate support for the platform 102 against gravity loads. Possible standard column shapes are shown in FIG. 5.

[0065]FIGS. 2A and 2B illustrate top views of an assembly 200 of two modules 100, in accordance with one or more embodiments of the present disclosure. For example, FIG. 2A illustrates the spacing of the ribs 106 on the platform 102, while FIG. 2B illustrates the location of the columns 112 possible in an assembly 200 of the two modules. As illustrated and described with reference to FIGS. 2A-2H, the assembly 200 may be able to resist at least 180 miles per hour wind and at least 12 feet of flood surge without having to depend on load bearing walls at the ground level.

[0066]As can be seen in FIG. 2B, the columns 112 need not be placed at the edge of the platforms 102. Instead, the columns 112 may be set in from the edge of the platform 102 by some amount. Additionally, when the modules 100 are positioned next to one another, columns 112 may be shared between the modules 100 on the edges of the modules 100 abutting each other. In this way, less material may be required, which, in turn, may reduce production costs.

[0067]FIGS. 2C and 2D illustrate cross-sectional end views of an assembly 200 of two modules 100, in accordance with one or more embodiments of the present disclosure.

[0068]Each platform 102 may be subject to a width restriction (e.g., 12 or 14 feet) in order to be able to be economically transported from a precasting factory to a jobsite. Therefore, it may be necessary to couple multiple modules 100 together in order to obtain the desired size of housing. As such, the modules 100 may be positioned next to each other and coupled at the platform 102, while the columns 112 remain uncoupled to neighboring columns 112 (e.g., if each module 100 includes a column 112 at each corner, the columns 112 at adjacent corners may not be coupled to each other). However, it should be noted that multiple modules 100 may share common columns 112 (e.g., a column 112 supports two different platforms 102).

[0069]FIGS. 2E and 2F illustrate a cross-sectional side view of a coupling between two modules 100, in accordance with one or more embodiments of the present disclosure.

[0070]For example, FIG. 2E shows coupling between two modules 100 at a rib 106 location, while FIG. 2F illustrates coupling between two modules 100 at a location other than a rib 106.

[0071]Coupling two modules 100 may include both filling a gap between the two modules 100 with a binding material 202 (e.g., ultra-high-performance concrete (UHPC) grout) and inserting a coupling member 204 (e.g., rebar) such that it connects the two modules 100. Many coupling members 204 may be used to couple the two modules 100.

[0072]It may be preferable for the binding material 202 to be a UHPC grout or grout of similar strength properties, to allow for shortened lengths of rebar overlaps. UHPC grout may refer to a material that is made up of micro and fine particle components. UHPC grout may include fibers (e.g., metal fibers) that increase the compressive and flexural strength of the UHPC grout. UHPC grout may display a compressive strength of about 18,000 to 35,000 pounds per square inch and a tensile strength of about 1400 pounds per square inch.

[0073]As can be seen from the FIGS. 2E and 2F, coupling at a rib 106 may result in a larger gap needed to be filled with the binding material 202. As such, coupling at a rib 106 may be the costlier option, as the binding material 202 may have a higher cost than the material used to form the platform 102.

[0074]The gap between the two modules 100 may be filled at the jobsite. In this way, the construction of the assemblies 200 may be simplified by only requiring the application of the binding material 202 and the installation of coupling members 204 to secure the modules 100 to one another.

[0075]FIGS. 2G and 2H illustrate perspective views of assemblies 200, in accordance with one or more embodiments of the present disclosure.

[0076]For example, FIG. 2G illustrates a simple assembly 200 with two modules 100 coupled to each other. Additionally, FIG. 2G includes a central column 112 between the two modules 100, if the interior architectural design allows for placement of such column within the living space. Otherwise, the interior space of the assembly may be designed to be free of columns to allow for great flexibility in the interior architectural design. The column 112 may be a hollow steel column, which may be used to route wiring through the assembly 200. In FIG. 2H, multiple assemblies 200 are coupled to one another and stacked on top of each other. In this way, FIG. 2H illustrates a multi-story building formed from the modules 100.

[0077]FIG. 3 illustrates a perspective view of the module 100 where the platform 102 is formed from two pieces, in accordance with one or more embodiments of the present disclosure. As illustrated and described, an assembly 200 formed from the module shown in FIG. 3 may be able to resist at least 180 miles per hour wind and at least 12 feet of flood surge without having to depend on load bearing walls at the ground level.

[0078]While monolithic platforms 102 may be desirable in some instances, a platform 102 formed from two or more pieces may be desirable, if weight limit is a significant cost factor or if the building site is restricted due to presence of adjacent houses. For example, a platform 102 formed from two or more pieces may allow for smaller equipment or easier erection due to reduced weight of the individual pieces. This may be important as certain jobsites may be limited in accommodating large capacity cranes, such as cranes that may be necessary to erect a monolithic platform 102.

[0079]In FIG. 3, the platform is formed by a skin 104 and a perimeter 108, where the skin 104 and the perimeter are individual pieces. The skin 104 and the perimeter 108 may be separately precast and delivered and erected separately at the jobsite. The skin 104 and the perimeter 108 may be coupled with a UHPC grout connection in order to emulate a monolithic platform 102, while avoiding the increased erection weight.

[0080]It is noted that the skin 104 may or may not include ribs 106. For example, due to the reduced weight of the individual components, the skin 104 may be thicker than in a monolithic platform 102, which would eliminate the need for ribs 106. However, the ribs 106 may still be included in order to balance weight and strength.

[0081]The perimeter 108 may include a lip 302 on its inner edge. The lip 302 may support the skin 104 and receive the UHPC grout to couple the skin 104 to the perimeter to form the platform 102.

[0082]FIG. 4A illustrates components of a module 100 where the platform 102 is formed from multiple (e.g., three or more) pieces. It is noted that the individual components of the module shown in FIG. 4A may each be individually precast and assembled at a jobsite to form the module 100 and an assembly 200. FIG. 4B illustrates an assembly 200 formed from the modules 100 of FIG. 4A. In FIG. 4B, it can be seen that the modules 100 shown in FIGS. 4A-4I are capable of forming a functionally identical assembly 200 to the modules 100 shown In FIGS. 1A-2H. Thus, as illustrated and described with reference to FIGS. 4A-4I, the assembly may be able to resist at least 180 miles per hour wind and at least 12 feet of flood surge without having to depend on load bearing walls at the ground level.

[0083]In embodiments, the platform 102 includes a slab 402. The slab 402 may be a flat slab (e.g., a slab 402 without ribs 106).

[0084]In embodiments, the platform 102 includes two inverted T beams 404 running parallel to each other. Each inverted T beam may include a central portion 406 and two side portions 408 flanking the central portion 406. The two side portions 408 may extend beyond the end of the central portion 406 such that on either end of the inverted T beam 404 a cavity 405 may be defined. Additionally, the central portion 406 may be thicker than the side portion 408 such that a ridge 410 is defined on either side of the inverted T beam 404 between the central portion and the side portions 408. The inverted T beam 404 may include one or more dowel holes 412.

[0085]In embodiments, the platform 102 includes two rectangular beams 414 running parallel to each other and intersecting the two inverted T beams 404. The rectangular beams 414 may include a notch 416 in at least two corners of the rectangular beams 414. Additionally, the rectangular beams 414 may include one or more dowel holes 412 and one or more rods 418 extending into the notch 416.

[0086]In embodiments, the column 112 may include one or more corbels 420 (e.g., a structure to vertically support other bodies). The one or more corbels 420 may be proportioned in a shallow thickness that does not negatively impact the interior ceiling height. Additionally, the column 112 may include one or more fastener holes 422 and one or more rod sleeves 424 (e.g., to receive the rods 418 of the rectangular beams 414.

[0087]FIGS. 4C-4I illustrate steps of assembling the components illustrated in FIG. 4A to form a module 100.

[0088]In FIG. 4C, a column 112 is shown. The column 112 may be the starting point for assembly of the module 100. The column 112 may be precast and designed to accommodate the total number of floors of the finished assembly 200. As shown, the column may include the corbels 420, the fastener holes 422, the rod sleeves 424, and one or more dowel bars 426.

[0089]In FIG. 4D, an inverted T beam 404 has been introduced. The inverted T beam 404 may be supported by the corbel 420 of the column 112 (e.g., at least the side portions 408 of the inverted T beam 404 may be supported by the corbel 420). Additionally, the inverted T beam 404 may be placed on the corbel such that the dowel bars 426 of the column 112 are inserted into the dowel holes 412 of the inverted T beam 404. The column 112 may also fit into the cavity 405 of the inverted T beam 404 such that the inverted T beam 404 partially encircles the column 112.

[0090]In FIG. 4E, fasteners 428 may be inserted into the fastener holes 422 of the column 112. The fasteners 428 may be threaded rods or bolts. The fasteners 428 may extend through the column 112 and bore into the inverted T beam 404. In this way, the fasteners 428 may couple the column 112 to the inverted T beam 404 in addition to the dowel bars 426.

[0091]In FIG. 4F, the rectangular beams 414 are placed on the corbel 420 of the column 112. Additionally, dowel bars 426 from the column 112 may extend upwards from the corbel 420 and into the dowel holes 412 on the rectangular beams 414. The notches 416 on the rectangular beams 414 may be positioned so they line up with the rod sleeves of the column 112. Therefore, the rods 418 of the rectangular beam may extend into the rod sleeves 424 of the column 112.

[0092]In FIG. 4G, a binding material 202 (e.g., UHPC grout) may be applied in order to secure the column 112, rectangular beams 414, and inverted T beam 404. The binding material 202 may be applied to the cavity 405 on the back of the inverted T beam 404, the notches 416 in the rectangular beams 414, the dowel holes 412, and/or the rod sleeves 424 on the column 112. After the binding material 202 cures, the column 112, inverted T beam 404, and rectangular beams 414 may effectively be a monolithic structure, though they were all individually precast. As the binding material 202 may be a UHPC grout, the binding material 202 may be a cement-based filling with special additions (e.g., discontinuous steel or synthetic fibers for strain-hardening).

[0093]In FIG. 4H, slabs 402 are added to the module 100. The slabs 402 may be placed on the ridge 410 of the inverted T beam 404, such that the inverted T beam 404 supports the slab 402 (e.g., the slab 402 rests on the ridge 410). In this way, the slab 402 may sit on the side portions 408 of the inverted T beam 404 and be bounded by the rectangular beams 414 and the central portion 406 of the inverted T beam 404.

[0094]In FIG. 4I, a concrete topping 430 is added to the module 100. The concrete topping 430 may be a poured on topping that fills any spaces existing in the module 100 after installation of the slabs 402.

[0095]FIG. 5 illustrates possible shapes of the columns 112 of the module 100, in accordance with one or more embodiments of the present disclosure. Particularly, FIG. 5 illustrates an L shaped column 112a, a rectangular column 112b, a T shaped column 112c, and a circular (e.g., steel tube) column 112d.

[0096]As nonlimiting examples, the L shaped column 112a and the rectangular column 112b may have a width of 8 inches, with corresponding lengths of 32 inches (2 feet 8 inches). Additionally, the steel tube column 112d may have a diameter of six inches. The T shaped column 112 c may include a length of 32 inches and a width of 16 inches, with 8-inch square cutouts on two corners to form the shape of the T shaped column 112c.

[0097]It should be noted that the columns 112 may have any height in order to facilitate spacing of different amounts. However, height of the columns 112 and/or the overall structure may be limited or dictated by local regulations and building codes.

[0098]Rectangular columns 112b and T shaped columns may support the platform 102 at its edges, while L shaped columns 112a may support the platform at its corners. Additionally, the circular column 112d may only be positioned internally in the modules 100 or an assembly 200 (e.g., between two modules 100 in an assembly). The circular column 112d may be optional, and may not be preferred in order to create open spaces in the assembly 200. However, the circular column 112d may provide for a path for wiring to reach various levels in the assembly 200.

[0099]FIGS. 6A-6C illustrate connections between the columns 112 and the platform 102 of the module 100, in accordance with one or more embodiments of the present disclosure. Additionally, FIGS. 6A-6C illustrate exemplary internal structures of the columns 112.

[0100]Each module 100 may include any number of reinforcement assemblies 602 between the columns 112 and the platform 102. The platform 102 and the columns 112 may be configured such that they may include a channel 604 to receive a sleeve 606. For example, the sleeve 606 may be made of a corrugated metal and/or be a galvanized metal. The channels 604 in the platform 102 may extend through the entire thickness of the platform 102, while the channels 604 in the columns 112 may only extend partway through the thickness of the columns

[0101]Each reinforcement assembly 602 may be formed inside of a channel 604. Each sleeve 606 may be configured to be filled with a filling 608 (e.g., UHPC grout) and a reinforcement member 610. In this way, the filling 608 may be a cement-based filling with special additions (e.g., discontinuous steel or synthetic fibers for strain-hardening). The reinforcement member 610 may be configured to be placed in the center of the sleeve 606 such that the reinforcement member 610 is completely surrounded by the filling 608. The reinforcement member 610 may be any rigid member. For example, the reinforcement member 610 may be a #8 Gr. 80 ASTM A615 Galvabar.

[0102]It is noted that the filling 608 may possess unique engineering properties, which may allow for the reinforcement members 610 to be effective over a length of only 8 to 10 reinforcement member (e.g., rebar) diameters, as opposed to conventional concrete grouts where the lap splice is 30 to 50 reinforcement member diameters.

[0103]The platform 102 and the columns 112 may be coupled via the reinforcement assemblies 602. For example, each reinforcement assembly 602 may extend partially into a column 112 and a platform 102. In such a way, the reinforcement assemblies 602 may work to couple the column 112 to the platform 102. Additionally, the reinforcement assembly 602 may extend all the way through the platform 102 in order to couple to an additional column 112 on top of the platform 102 (e.g., to add an additional story to a structure). The filling 608 may act to couple the columns 112 to the platform 102 based on the filling 608 completely filling the space in the channel 604 not taken up by the sleeve 606 and the reinforcement member 610.

[0104]FIGS. 7A and 7B illustrate connections between the columns 112 of the module and a footing 702, in accordance with one or more embodiments of the present disclosure.

[0105]For example, each column 112 may couple to the footing 702 with by a footing plate 704. The footing plate 704 may be partially sunk into the footing 702 and further include connections into the footing 702. The footing plate 704 may include a receptacle 706 that is configured to receive and secure the column 112, thus coupling the column 112 to the footing 702.

[0106]It should be noted that the term footing 702 as used herein may broadly be any component used to secure a structure to the ground. As such, the footing 702 illustrated in FIG. 5 should be interpreted as illustrative rather than limiting.

[0107]FIGS. 8A and 8B illustrate a cross-sectional side view of a coupling between two modules 100, in accordance with one or more embodiments of the present disclosure. The illustration of FIGS. 8A and 8B is largely the same as the illustration in FIGS. 2E and 2F, as shown above.

[0108]As illustrated, two platforms 102, and thus two modules 100, can be coupled at either a location of a rib 106 or at any point on the perimeter 108 of the platform. During precasting of the platforms 102, spaces may be created to allow for coupling between the two platforms 102. The space may be filled with a binding material 202 (e.g., UHPC grout) and coupling members 204 may extend between the two platforms 102.

[0109]FIG. 9 illustrates connection of a floor 901 to the platform 102 of a module 100, in accordance with one or more embodiments of the present disclosure. For example, FIG. 9 illustrates a thermally insulated connection between the platform 102 and the floor.

[0110]For example, the floor 901 above the platform may be built up in layers from the skin 104 of the platform 102 up. In embodiments, the floor 901 includes a layer of insulation 902. For example, the insulation 902 may be an extruded polystyrene (XPS) insulation 902. In embodiments, the floor 901 includes a layer of cast in place (CIP) topping 904. For example, the CIP topping 904 may be poured over the floor 901 at the jobsite and let to cure to form a solid surface. In embodiments, the floor 901 includes flooring 906 on top of any preceding layers. The flooring 906 may include, but is not limited to, carpet, tile, linoleum, or hard wood.

[0111]It should be noted that the layers of the floor 901 as illustrated in FIG. 9 are illustrative rather than limiting, as the floor 901 may include any number of layers, which may be composed of any material suitable for incorporation into a floor 901. For example, the floor 901 may or may not include an insulation 902. Additionally, if the platform 102 is formed from two or more pieces (e.g., as in FIGS. 3-4I), insulation 902 may only be located over the skin 104 portion of the platform 102.

[0112]Additionally, FIG. 9 illustrates a possible wall assembly 908. For example, FIG. 9 includes a concrete masonry unit (CMU) 910 used to form the wall assembly 908. The concrete masonry unit 910 may be coupled to the platform 102 with any attachment mechanism or attachment embed 912 known in the art. For example, the attachment embed 912 may be TigerLoc or any other high density polyethylene plank. Additionally, interior of the concrete masonry unit 910, there may be a layer of insulation and/or a furring strip 914. The interior layer of the wall assembly 908 may be drywall 916 or any other desired product.

[0113]The module 100 may be designed in such a manner that exterior walls comprising the concrete masonry unit 910 may be configured for use with an 8 inch×16 inch×8 inch concrete masonry unit 910.

[0114]It should be noted that the interior and the exterior of a completed house made with the module 100 may be highly customizable. For example, the exterior may be any exterior used in construction houses, such as, but not limited to, wood, steel stud walls, or UHPC white cement cladding wall panels. By way of another example, the interior may be a prefabricated modular unit, which may provide for quick erection and occupancy, or a custom, “stick built,” wood framed interior.

[0115]FIGS. 10A and 10B illustrate a concrete roof 1002, in accordance with one or more embodiments of the present disclosure.

[0116]The concrete roof 1002 may be configured such that it has a small overhang on the sides (e.g., extends over the platform 102 and the columns 112). Additionally, the concrete roof 1002 may have a peak in the middle and slant outwards to facilitate drainage of water away from the module 100 and/or the assembly 200.

[0117]It is contemplated that in high-wind scenarios, traditional roofs are typically the weakest point on a house and may be blown off, creating flying debris propelled by high wind speeds. Additionally, traditional shingle roofs may see significant damage from hail storms that require replacing the roof. Therefore, a concrete room may provide significant benefits over traditional roofs. However, it should be noted that traditional, pitched roofs, may still be used in conjunction with the module 100 and/or an assembly 200 of modules 100. Thus, a concrete roof 1002 may be desirable in areas at high risk for natural events that are prone to damaging roofs, while not necessary in areas that are at a low risk for natural events that are prone to damaging roofs.

[0118]FIGS. 11A and 11B illustrate a precast wall cladding panel 1102, in accordance with one or more embodiments of the present disclosure.

[0119]The precast wall cladding panel 1102 may be used as an alternative to the concrete masonry unit 910 discussed with reference to FIGS. 11A and 11B. As an illustrative example, the precast wall cladding panel 1102 may include a form liner 1104 and insulation 1106 in front of the column 112. Additionally, the precast wall cladding panel 1102 may be connected with a tie back 1108 and a bearing 1110.

[0120]FIGS. 12A and 12B illustrate an assembly 200 of modules 100 in a coastal area, in accordance with one or more embodiments of the present disclosure. For example, FIG. 12A is a top view of the assembly 200 of modules 100, while FIG. 12B is a side view of the assembly 200.

[0121]For example, FIG. 12B illustrates a total of 8 modules 100 that are connected in order to create an assembly 200 (e.g., the frame of a house). In FIG. 12B, the lower level 1202 formed by three modules 100 is designed to be left empty (e.g., no walls or interior fixtures) in order to protect against flooding. While the lower level 1202 may be left without walls, it may still be used for storage, parking, or the like. Such a lower level 1202 of an assembly 200 may be referred to as a soft story.

[0122]Additionally, FIG. 12B illustrates at most four modules 100 stacked on top of each other. While it is possible that any number of modules 100 may be stacked on top of each other, it is contemplated that certain areas or municipalities may limit the height of structures. As an illustration, the structure in FIG. 12B may be limited to 39 feet 10 inches which conforms to the regulations of some coastal areas.

[0123]It should be noted that in a configuration where the lower level 1202 must be left empty due to flooding risks, utilities (e.g., water and electric) may be able to reach the living area in any number of ways. For example, utilities may reach the living area through the empty space in the lower level. By way of another example, utilities may reach the living area through conduits coupled to the columns 112. By way of another example, the columns 112 may be designed such that utilities travel through one or more of the columns 112 (e.g., through a hollow opening or passages extending at least part of the length of the column 112).

[0124]FIG. 12C illustrates floor layout for the assembly 200 of modules 100 in a coastal area, in accordance with one or more embodiments of the present disclosure.

[0125]The floors in FIG. 12C correspond to the floors illustrated in FIG. 12B. It should be noted that no lower level 1202 is shown in FIG. 12C, as that area is designed to be open space to protect against flooding. It should be noted that the space utilization shown in FIG. 12C is illustrative, rather than limiting, and space may be utilized in any way. For example, a second floor 1204 may be used for a main living space may or may not include bedrooms, the third floor 1206 may be used primarily for bedrooms, and the fourth floor 1208 may be an open deck.

[0126]FIG. 13 illustrates an assembly 200 of modules 100 in a midwestern region of the United States, in accordance with one or more embodiments of the present disclosure.

[0127]It should be noted that there are several notable differences between houses that may be constructed from the module 100 in the Midwest, as compared to coastal areas. For example, midwestern homes may have a basement 1302, which may be desirable for protection during tornadoes and other serious storms. This may not be possible in coastal areas due to ground conditions and the possibility of flooding. Additionally, the ground floor 1304 is not used as an open space because in many midwestern locations the danger of flooding is significantly lower than the coast. Additionally, the second floor 1306 may be used for bedrooms, or as a deck or garden, similar to houses in a coastal area.

[0128]However, it should be noted that many of the dimensions used in midwestern construction are still configured to be dimensions appropriate for use with the module 100 (e.g., dimensions in multiples of 12). Therefore, even though design considerations may change depending on location, the module 100 may have significant unitality regardless of where it is constructed.

[0129]FIG. 14 illustrates an example of an assembly 200 of modules 100, in accordance with one or more embodiments of the present disclosure.

[0130]In FIG. 14, two modules 100 are stacked upon each other to create an assembly 200. However, the two modules 100 are not stacked such that they line up. Instead, the modules 100 are stacked to create an L shape. In this way, one module 100 is cantilevered over the other module 100.

[0131]It should be noted that the assemblies 200 illustrated herein should be interpreted as illustrative rather than limiting, as modules 100 may be oriented in any manner in an assembly 200.

[0132]FIG. 15 illustrates a flow diagram depicting a method 1500, in accordance with one or more embodiments of the present disclosure. Applicant notes that the embodiments and enabling technologies described previously herein in the context of the module 100 and/or the assembly 200 should be interpreted to extend to the method 1500. It is further noted, however, that the method 1500 is not limited to the architecture of the module 100 and/or the assembly 200.

[0133]In embodiments, the method 1500 includes a step 1502 of precasting one or more platforms, wherein each platform includes a skin, a perimeter, and a plurality of ribs. Precasting may refer to the process for precast concrete which is a construction product made by pouring concrete into a mold in a factory or plant, then transporting the cured concrete to the construction site for installation. For example, the platform may be precast as a single, monolithic piece of material. Additionally, the platform may be precast from high performance concrete. High performance concrete may be a type of concrete that is designed to be stronger and more durable than regular concrete. As an example, higher performance concrete may display twice the strength of regular concrete. By way of another example, high performance concrete may be configured to have a strength capable of sustaining 8000 pounds per square inch.

[0134]In embodiments, the method 1500 includes a step 1504 of precasting one or more columns configured to support the one or more platforms. The columns may be precast in rectangular shapes or L shapes to accommodate various locations of the platform where the columns will be mounted.

[0135]In embodiments, the method 1500 includes a step 1506 of transporting the one or more platforms and the one or more columns to a jobsite. For example, the one or more platforms and the one or more columns may be placed on a trailer (or multiple trailers) and brought to the jobsite with a semi. This step 1506 may be one of the limiting factors in the size of the platform and/or the columns, as the width and/or length of the platform may be restricted by restrictions on roads.

[0136]In embodiments, the method 1500 includes a step 1508 of coupling the one or more columns to the one or more platforms to create one or more modules, wherein the one or more columns are coupled to the one or more platforms with a reinforcement assembly. The reinforcement assembly may extend partially into the platform and the column. Additionally, at least a portion of the reinforcement assembly may extend through the platform to couple the module to another module.

[0137]In embodiments, the method 1500 includes a step 1510 of creating an assembly by coupling the one or more modules to another module with at least one of ultra high-performance concrete (UHPC) grout or a coupling member. An assembly may include modules placed on top of each other (e.g., stacked) and/or next to each other (e.g., side by side). For example, when the modules are assembled next to each other, sections of the platforms may be filled with UHPC group and/or a coupling member. By way of another example, When the modules are placed on top of each other they may be coupled to each other by a reinforcement assembly.

[0138]Additionally, it is contemplated that assemblies may vary greatly depending on local regulations and conditions. For example, in some locations an assembly may have limited height and/or it may not be feasible to have a basement. By way of another example, an assembly may need to have an empty first story to protect against flooding.

[0139]It should be noted that when creating an assembly from multiple modules, the module may be placed on or next to or on top of a module with the same dimensions and/or orientation as other modules. However, the module may be placed on or next to or on top of a module with different dimensions and/or orientation as other modules.

[0140]The herein described subject matter sometimes illustrates different components contained within, or connected with, other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “connected” or “coupled” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “couplable” to each other to achieve the desired functionality. Specific examples of couplable include but are not limited to physically interactable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interactable and/or logically interacting components.

[0141]It is believed that the present disclosure and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction, and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes. Furthermore, it is to be understood that the invention is defined by the appended claims.

[0142]Further, it should be understood that any dimensions recited in the drawings and/or text of the present application should be considered illustrative rather than limiting.