System and method for modular construction

Abstract

A building module for use in construction of a building comprising a deck oriented in a horizontal plane and a plurality of hollow structural members extending downwardly from around a periphery of the deck. A method of constructing a building comprising placing a plurality of prefabricated modules according to a floor plan to form a story of the building, pouring concrete into the hollow structural members of the plurality of modules to form structural columns, pouring concrete onto the decks of the plurality of prefabricated modules for form structural slabs, and allowing the structural columns and structural slabs to set to complete the story of the building. Embodiments include a plurality of techniques for sealing adjacent prefabricated modules and for installing a balcony on the prefabricated modules.

1 . A building module for use in construction of a building, the module comprising:
 a deck oriented in a horizontal plane; and   a plurality of hollow structural members extending downwardly from around a periphery of the deck, wherein the deck is configured to support and engage concrete poured onto the deck.   
     
     
         2 . The building module of  claim 1  wherein the deck comprises one or more reinforcement members attached thereto and configured to provide structural support for a slab of set concrete formed on top of the deck. 
     
     
         3 . A building comprising:
 at least one deck oriented in a horizontal plane;   a plurality of prefabricated modules disposed above and below the deck;   a plurality of hollow structural members extending downwardly from around the periphery of each prefabricated module; and   a gasket disposed between adjacent prefabricated modules, wherein the gasket includes an enclosure containing a two-part expanding foam and a manually actuated mechanism that when pulled manually causes the two-part expanding foam to expand, thereby creating a seal between the two adjacent prefabricated modules.   
     
     
         4 . The building according to  claim 3  wherein the gasket is attached to one of the vertical structural members 
     
     
         5 . A building comprising:
 at least one deck oriented in a horizontal plane;   a plurality of prefabricated modules disposed above and below the deck;   a plurality of hollow structural members extending downwardly from around the periphery of each prefabricated module; and   and exterior closure assembly comprising:
 an exterior building panel having a mating surface with a gasket thereon configured to make contact with an exterior surface of an adjacent prefabricated module; 
 a rotating shaft attached to the exterior building panel and having at least one hinge attached thereto, the hinge also being attached to an adjacent prefabricated module; 
 one end of the rotating shaft having a turning mechanism for manually rotating the shaft from a location outside the exterior building panel, wherein rotating the shaft causes the mating surface to come into sealing contact with the exterior surface of the prefabricated module. 
   
     
     
         6 . A building comprising:
 at least one deck oriented in a horizontal plane;   a plurality of prefabricated modules disposed above and below the deck;   a plurality of hollow structural members extending downwardly from around the periphery of each prefabricated module; and   a gasket disposed between adjacent prefabricated modules, wherein the gasket comprises:   a steel form track system installed onto each prefabricated module;   an insulated compression bubble gasket configured to fit inside the steel form track system; and   an attachment to the gasket to enable the gasket to be manually pulled through the steel form track system to thereby compress the gasket between the adjacent modules.   
     
     
         7 . A building comprising:
 at least one deck oriented in a horizontal plane;   a plurality of prefabricated modules disposed above and below the deck;   a plurality of hollow structural members extending downwardly from around the periphery of each prefabricated module, wherein the hollow structural members comprises:
 a plate disposed at one end of the hollow structural member; and 
 angled self-alignment pins disposed on the plate and configured to be inserted into the inside of an adjacent hollow structural member. 
   
     
     
         8 . A building comprising:
 at least one deck oriented in a horizontal plane;   a plurality of prefabricated modules disposed above and below the deck;   a plurality of hollow structural members extending downwardly from around the periphery of each prefabricated module;   a balcony unit including balcony decking and horizontal steel tubes;   the prefabricated module including a plurality of brackets with openings configured to receive the ends of the steel tubes, wherein during installation of the balcony the steel tubes are inserted into the bracket openings; and   concrete disposed on the decking and encapsulating the brackets and the ends of the steel tubes.   
     
     
         9 . A method of constructing a building comprising:
 placing a plurality of modules according to a floor plan to form a story of the building, each module comprising a deck oriented in a horizontal plane and a plurality of hollow structural members extending downwardly from around a periphery of the deck;   pouring concrete into the hollow structural members of the plurality of modules to form structural columns;   pouring concrete onto the decks of the plurality of modules for form structural slabs; and   allowing the structural columns and structural slabs to set to complete the story of the building.