Modular building structure

A building is constructed substantially entirely from flat panel modules including a plurality of planar wall modules supported on a base and having at least one vertical load bearing member internal thereto extending from a bottom portion of the wall module to a top portion of the wall module in order to transmit the weight of a load above the module to the base. The load bearing member includes a conduit strut positioned between inner and outer surface members and free-standing conduit struts joining adjacent wall modules. The floor, ceiling and roof are each defined by a plurality of generally horizontal modules, each of which has either an upper or lower surface member, which is appropriately finished and at least one generally horizontal beam extending substantially the entire length of one module edge and positioned to support an unsupported edge of the adjacent module. A unique supporting system is provided for supporting the ceiling module and the roof rafters including a rafter bracket fastened to an end of each roof rafter, which is supported by a ridge bracket straddling a ridge beam, a compression strut between a central portion of each roof rafter and a portion of the subjacent ceiling rafter and a flexible tension member extending between the ceiling rafter and ridge bracket.

BACKGROUND OF THE INVENTION 
This invention relates to building structures and in particular to a 
modular building construction that utilizes flat panel modules. 
Prefabricated modular building structures, particularly residential 
buildings, are well known. A typical construction technique is to 
manufacture the building in a factory in several large modules that each 
comprise several rooms and to assemble the modules together at the site. 
The problem is that, because the modules are mostly empty space, the 
shipping costs are enormous and require that the factory be located close 
to the site of assembly. 
Attempts have been made at providing building structures assembled from 
flat-panel modules. One such example is U.S. Pat. No. 4,435,928 issued to 
Huling for a LOW ENERGY BUILDING, which utilizes a wooden post-and-beam 
framing system with a prefabricated insulated panel system, in which the 
panels are applied to the exterior surface of the frame. The requirement 
for a separate frame involves not only a separate assembly step, but also 
the coordination of design of the frame with that of the modules for 
different building configurations. 
A modular building system disclosed in U.S. Pat. No. 4,125,972 issued to 
Pate for a MONOCOQUE CELL eliminates the necessity for a separate frame by 
providing interlockable modular elements. The system disclosed in Pate 
requires that each modular element be custom designed for its particular 
location in the building and produces an appearance that is 
non-traditional and, therefore, subject to consumer resistance. 
SUMMARY OF THE INVENTION 
It is an object of the present invention to provide a modular building 
structure that is based upon flat panel design to reduce shipping cost and 
facilitate shipment over great distances, even overseas. A high quality 
product is provided which reduces heat loss and noise penetration while 
improving durability and maintainability. This is accomplished in a manner 
that provides virtually any aesthetic appearance to any wall structure in 
order to accommodate virtually any architectural styling and thus ensure 
acceptance by the public. The invention may be embodied in a building 
having at least one horizontal floor, a ceiling above the floor, a 
generally vertical wall extending between the floor and the ceiling in 
order to define a perimeter of the building, and a roof above the ceiling. 
According to one aspect of the invention, the vertical wall is defined by 
an elongated base and a plurality of generally planar wall modules 
supported on the base. Each of the wall modules has an inner surface 
member, an outer surface member, and at least one vertical load bearing 
member extending from a bottom portion to a top portion thereof between 
the inner and outer surface members. The internal load bearing member 
transmits the weight of the load above the module to the base and, 
thereby, eliminates the necessity for a separate frame work. The inner and 
outer surface members may be finished in any desirable fashion to take on 
the appearance of wood panelling, painted walls, mirrored walls, stucco, 
brick and the like. 
The present invention provides a building structure that accommodates all 
of the utilities required for residential use such as power and 
communications wiring and plumbing. This is accomplished in a manner that 
provides for future modifications to the wiring and plumbing for 
flexibility. According to another aspect of the invention, each of the 
planar wall modules includes insulation between the inner and outer 
surface members and a vertical conduit member positioned between the inner 
and outer surface members and extending vertically through the module such 
that the conduit defines a through-passage in the insulation. At least one 
of the lateral edges of the module may have a configuration that defines a 
conduit-receiving space with an adjacent wall module. In this manner, a 
second conduit member may be positioned between adjacent wall modules. 
Horizontal conduit members may additionally be provided in the wall panels 
to intersect with the vertical conduit members to provide additional 
flexibility in utility layout. 
The above is accomplished in a manner that utilizes advanced manufacturing 
techniques and materials that are capable of being recycled, such as 
ceramic, glass, plastic and aluminum. According to another aspect of the 
invention, the wall module is produced by an in-situ foaming of the 
interior of the wall modules in order to form the insulation. The foam may 
be deposited by one or more elongated nozzles having an end configured to 
plug an opening in the vertical conduit in order to prevent foam from 
entering the vertical conduit. As the elongated nozzle is withdrawn from 
the module, it leaves behind a horizontally disposed passageway opening to 
the interior of the vertical conduit. By lining the horizontal opening 
with a sleeve, a fully protected horizontal conduit is defined in the 
panel intersecting with the vertical conduit. Furthermore, in order to 
provide for traditional exterior appearances, such as field stone, brick, 
stucco and the like, the outer surface member may be clad with a metal 
sheet, such as aluminum, that is stamped to simulate a particular design. 
By placing openings through a supporting sheet, the foam reaches 
interstices between the support sheet and the pattern metal sheet for 
durability and further insulation. 
In order to obtain maximum reduction in shipping cost and on-site labor, 
the present invention carries the flat panel module approach to the other 
structures of the building including the floor, ceiling and roof 
structures. According to another aspect of the invention, each of the 
floor, ceiling and roof may be made from horizontal modules having either 
an upper or a lower surface member, or both, and at least one generally 
horizontal beam extending substantially the entire length of the module 
along one edge thereof. The beam is positioned with respect to the panel 
surface member such that, when adjacent modules are joined, an unsupported 
edge of one module is supported by the horizontal beam of the adjacent 
module. Each module may also include a second beam running parallel with 
the one beam midway between the lateral edges of the module. One or more 
brace members may be provided to selectively brace the edges of the beams 
that are spaced from the surface member during shipment and be 
repositioned to provide cross-beam bridging support to the structure when 
assembled with adjacent modules. 
According to yet another aspect of the invention, the building roof may be 
defined by a central ridge beam and first and second roof portions pitched 
downwardly and outwardly from the ridge beam. A force distribution system 
may be provided to support the roof including a compression strut 
extending from a central portion of each roof rafter to a support rafter 
and a tension cable extending between the ridge beam and the support 
rafter. Various components of such force distribution system may be 
stamped from sheet metal and, hence, made in a light weight, yet sturdy, 
fashion with good fire-resistance characteristics. 
These and other objects, advantages and features of the invention will 
become apparent upon review of the following specification in conjunction 
with the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now specifically to the drawings and the illustrative embodiments 
depicted therein, a building 40 is constructed of flat-panel modules 
including a plurality of floor modules 42, a plurality of ceiling modules 
44 and a plurality of wall modules 46 supporting ceiling modules 44 above 
floor modules 42 (FIG. 1). If the building 40 is to be two or more 
stories, as illustrated, a plurality of combination floor/ceiling modules 
48 separate the stories. In the latter case, a first set of wall modules 
46 support the floor/ceiling modules separating the stories and a second 
set of wall modules 46 support the ceiling modules 44 from the uppermost 
set of floor/ceiling modules. Building 40 additionally includes a 
plurality of roof modules 50 supported above ceiling modules 44. Building 
40 is illustrated assembled on a conventional foundation wall 52 and 
bearing plate 54. 
Each floor module 42 and floor/ceiling module 48 includes a base plate 56 
having a domed, or convex, surface 58 upon which the wall modules 46 are 
positioned. In a similar fashion, ceiling modules 44 and floor/ceiling 
modules 48 have downwardly extending top plates 60 with convex surfaces 62 
for engaging the uppermost portions of modules 46. Convex surfaces 58 and 
62 engage, respectively, bottom concave surface 64 and top concave surface 
66 of wall modules 46 (FIG. 3). The interface between the convex and 
concave surfaces provides a self-alignment of the wall modules with 
respect to their base plates and top plates in order to provide close 
tolerances between the panels and to avoid deviations from the interior or 
exterior planar wall surfaces. 
Each wall module 46 includes an upper end plate 68 and lower end plate 70, 
which are made from rigid foam plastic or wood or similar material, and 
spaced apart interior surface panel 72 and exterior surface panel 74 
extending between upper and lower end plates 68, 70 (FIGS. 2-8). A conduit 
stud 76, which is load-bearing, extends between lower end plate 70, where 
it is supported by a land 97, and upper end plate 68 where it acts against 
a land 97, in order to transmit forces from end plate 68 to end plate 70. 
In the illustrated embodiment, conduit stud 76 is extruded aluminum but 
could be made of other materials including PVC, structural plastics or the 
like. Conduit stud 76 includes an internal passageway 78 elongated in the 
vertical direction and opening to a through-hole 80, in upper end plate 
68, and through-hole 82 in lower end plate 70. In this manner, a 
through-passage is defined vertically in each wall module 46. Openings 77 
and 79 in conduit stud 76 connect with an upper horizontal conduit 84 and 
a lower horizontal conduit 86. Each horizontal conduit 84, 86 is lined by 
a conduit insert 88, which may be made of PVC or other conduit material. 
In this manner, one or more horizontally oriented through-passageways are 
defined in each wall module 46. The space between interior surface panel 
72 and exterior surface panel 74 is filled with an in-situ formed urethane 
foam 90 of the type commonly utilized to insulate refrigerator and freezer 
cabinets. 
Each wall module 46 additionally includes camming surfaces 92a, 92b, 92c 
and 92d for providing self-actuating fitting between adjacent wall 
modules. Downward facing camming surface 92a is located on a portion of 
upper end plate 68 extending beyond interior surface panel 72 and slopes 
downwardly away from the module. Upward facing camming surface 92b is 
positioned within the lateral edges of surface panels 72, 74 and slopes 
downwardly toward the respective panel 46. Downward facing camming surface 
92c is within the lateral edges of surface panels 72, 74 and slopes 
downwardly away from the module. Upward facing camming surface 92d extends 
beyond surface panels 72, 74 and slopes downwardly. In this manner, when 
adjacent panels 46 are positioned, as illustrated in FIG. 4, the camming 
surfaces are actuated by the weight of the modules to pull the modules 
together. 
Conduit stud 76 includes oppositely extending wings 94a, 94b in order to 
support, respectively, interior surface panel 72 and exterior surface 
panel 74 to which the conduit stud may be attached by suitable adhesive. 
Each wall module 46 has concave lateral side edges 96 and 98 which are 
configured to define a vertically extending shaft in which may be 
positioned a separate split conduit stud 76'. Conduit studs 76' provide 
additional load-bearing support for superjacent floor/ceiling modules 48 
or ceiling modules 44. Additionally, conduit studs 76' provide 
through-passages 78' which may be used for pipe-chases, wiring conduits or 
the like. If desired, wings 94a' and 94b' on conduit stud 76' may be 
configured to receive screws or fastening portions of seam covers (not 
shown) for covering seams between adjacent interior surface panel 72 or 
exterior surface panel 74. Where vertical passage for utilities is not 
required and heavier vertical loads are being supported by the wall 
module, the conduit stud 76, 76' may be substituted by 
A preferred technique for covering the seams between interior surface panel 
72 is illustrated in FIG. 9 and includes providing beveled edges 100a and 
100b on adjoining panels 72 and a bead 102 of caulking or pressure release 
adhesive material along edge 100b. Accordingly, when wall modules 46 are 
brought together bead 102 will be evenly spread between beveled edges 
100a, 100b. A flexible flap 104, an extension of the decorative covering 
over the inside panel 72, can then be smoothed over the joint, releasing 
the adhesive on an undersurface thereof to the adjoining interior surface 
panel 72 in order to cover the seam. Other conventional dry-walling 
seam-covering techniques may be utilized. In the illustrated embodiment, 
interior surface panel 72 may be made from conventional gypsum board, or 
plywood or particle board covered with a suitable surface treatment such 
as paper, mirror panels, wood panelling, marble or other conventional 
interior finishing materials. 
Wall modules 46, as best seen in FIG. 3, have the desirable feature of 
being extremely durable for transportation purposes. Interior and exterior 
surface panels 72, 74 are capped by upper and lower end plates 68 and 70 
so that no portion of the surface panel extends beyond the end plate. 
However, the wall modules 46 require conventional floor molding and 
ceiling molding (not shown) in order to cover the otherwise exposed seam 
between upper plate 68 and top plate 60 and between lower plate 70 and 
base plate 56. Likewise, a horizontal molding will be required for 
exterior surfaces to cover such seam. In an alternative wall module 46' 
interior and exterior surface panels 72', 74' protrude above upper end 
plate 68 and below lower end plate 70 (FIG. 7). The advantage of wall 
modules 46' is that the base plate 56 below the wall module 46' and the 
top plate 60 above the upper end plate are covered by the interior surface 
panel 72' and exterior surface panel 74'. Accordingly, there is no 
requirement for separate ceiling and floor molding or for exterior 
horizontal molding. However, the portions of interior surface panel 72' 
and exterior surface panel 74' that extend beyond upper and lower end 
plates 68, 70 are exposed to damage in shipment and require more bracing 
during transit. Wall modules 46' have an additional advantage of being of 
the same thickness as conventional walls when plates 56 and 60 are formed 
from two-by-four boards. Wall modules 46 would be no wider than the 
two-by-four itself, which will provide less insulation-receiving space 
between the interior and exterior panels, which is an advantage for 
non-load bearing walls 46'' as illustrated in FIG. 28. However, when 
plates 56, 60, 68, 70 are made in rigid foam or with wider lumber, 
conventional-width wall modules 46 can be offered to customers. In the 
illustrated embodiment, wall modules 46 and 46' are 48 inches wide and 
97'' and 96'' inches high, respectively. 
Exterior surface panel 74, in the illustrated embodiment, includes a 
support panel 106, which may be made from water-resistant particle board, 
plywood, gypsum board, or the like, and a metal or plastic clad 108 
adhered to panel 106 (FIGS. 10 and 11). Clad 108 may be formed, by 
conventional techniques, to have the appearance of brick, as illustrated, 
or field stone, stucco or the like. A plurality of openings 110 through 
support panel 106, provide access to the area behind clad 108 in order 
that the liquid foam may fill the interstices between clad 108 and panel 
106 during the manufacturing operation. After curing, the foam adheres the 
clad to the support panel and provides solid backing for the relief of the 
clad so that it is less subject to damage during use. Clad 108, in a 
preferred embodiment, is prepainted aluminum. 
An apparatus 111 for manufacturing wall modules 46 includes an incoming 
conveyor 112, an outgoing conveyor 114 and a transfer conveyor 116 to 
transfer wall modules 46 to and from a foaming fixture 118 (FIGS. 12 and 
13). Foaming fixture 118 includes fixed lower 120B and moveable upper 
platens 120A and lateral cores 122a, and 122b. A module shell (not shown); 
including surface panels 72, 74, end plates 68, 70 and conduit stud 76 
connected together; is transfered by transfer conveyor 116 to the space 
between platens 120a, 120b and lateral cores 122a, 122b. Retractable 
injectors 124a, 124b, 124c and 124d are provided and include elongated 
injector nozzles 126a, 126b, 126c and 126d, respectively. Each nozzle 
126a-126d is longitudinally movable with respect to its associated core 
122a, 122b such that when the injectors are extended, the nozzles are 
positioned in the area between platens 120a and 120b and, when retracted, 
the nozzles are withdrawn from this area. When the injectors are extended, 
the outermost tips of nozzles 126a-126d engage openings 77 and 79 in 
conduit stud 76 in a manner that plugs the respective openings 77, 79. 
In this manner, liquid polyurethane foam, which is injected from side 
passages 127 in nozzles 126a-126d, is kept from internal passage 78 of 
conduit stud 76. Furthermore, when the retractable injectors are 
retracted, the nozzles leave behind a passage extending from openings 77 
and 79 laterally through the side of the wall module 76 to provide the 
opening for horizontal conduits 84, 86. After foaming, an ejector 128 
forces the wall module onto transfer conveyor 116 and to subsequent 
operations (not shown) in which conduit inserts 88 are placed in the 
openings left by nozzles 126a-126d to complete a wall module 46. In 
addition to polyurethane foam, insulation 90 can be manufactured from 
expanded styrene beads, in which case, nozzles 126a-126d would inject 
steam in order to expand the beads which would be deposited between 
surface panels 72, 74 by other means (not shown). 
Each floor module 42 includes an upper surface member 130 which may be 
finished in carpet, tile, or the like, or may be left as unfinished 
particle board or plywood in order to accommodate subsequent finishing, if 
desired (FIG. 14). A first horizontal member, such as a joist 132, extends 
the full length of floor module 42 along a first edge 134 of the upper 
surface member 130 in a manner that fabricated joist 132 extends laterally 
beyond edge 134. A second horizontal support member, or joist 136, runs 
parallel with joist 132 and generally midway between edge 134 and an 
opposite edge 138. Edge 138 is unsupported by a joist, but when assembled 
against an adjacent module, is supported by the portion of Joist 132 that 
extends laterally beyond edge 134. A plurality of shipping braces 140, 
which are spaced along the length of floor module 42, support the lower 
ends of joists 132, 136 during shipment. When the module is installed in 
building 40, however, shipping brace 140 is repositioned to the dotted 
line position in FIG. 14 for connection with the adjoining joist 132. A 
bridge strut 141 extends from a lowermost portion of joist 136 and is 
connected to edge 138 of the module which is supported by an edge brace 
board 143 which extends to the full module length. Another bridge strut 
142 is connected to the top of joist 132 and extends to the bottom of 
joist 136. Struts 141, 142 are spaced along the length of the module in 
order to support that portion of upper surface member 138 during shipment 
and bottom of joints after installation. 
In the illustrated embodiment, floor module 42 is 32 inches wide in order 
to provide 16 inch joist spacing. The module may run the entire width of 
building 40, as viewed in FIG. 1, or may be supported by a center 
load-bearing beam or wall (not shown) that runs the length of building 40. 
A finishing floor module 42' is similar to floor module 42 except that 
edge 134 is located flush with the outer edge of joist 132. A squash board 
144' and a facia panel 146' provide a finished appearance. A starter 
module 42'' is further fitted with a joist 148 to support edge 138 of that 
module. Both ends 150 (only one of which is shown in FIG. 1) of floor 
modules 42 are completed in a joist and finished with a squash board and 
facia panel similar to that illustrated in FIG. 14. Base plate 56 is 
positioned on ends 150 of floor modules 42 and along full length of one 
side each of starter and finishing modules 42' and 42''. 
Ceiling modules 44 include a lower finished surface member 152 which, in 
the illustrated embodiment, is gypsum board, but could be any other 
material previously mentioned if desired (FIGS. 15-17). Surface member 152 
is supported by a horizontal member, such as a ceiling joist 154, along 
edge 156 of the module in a manner that fabricated joist 154 extends 
laterally beyond lateral edge 156 of surface member 152. A central joist 
158 is provided that is parallel with joist 154 and runs the entire length 
of module 44 approximately midway between edge 156 and an unsupported edge 
160. A plurality of bridge struts 162, spaced along the length of panel 
44, extend between an uppermost portion of joist 158 and lowermost portion 
of joist 154. A plurality of bridge struts 164, spaced along the length of 
panel 44, extend between an uppermost portion of joist 158 and an edge 
brace 166. A resilient spring clip 168 is formed to extend under edge 
brace 166 and over a portion of the joist 154 of the adjacent ceiling 
module 44. The purpose of spring clip 168 is to provide an upward support 
of edge 160 from joist 154 of the adjacent module and align with adjoining 
edge 156. An alternative arrangement is illustrated in FIG. 17 in which an 
alignment member 170 extends from a metal bridge strut 172 to edge brace 
166 an adjustment screw 174, which allows relative adjustment of edge 160 
with respect to edge 156 of the adjoining ceiling module. 
As best seen in FIG. 16, joists 154 and 158 may be a solid wood beam but 
may, alternatively, be a TJI joist or other joist fabricated from 
engineered lumber. If desired, joists 154, 158 may be fabricated using 
gang nail reinforcing plates. If so, it would be contemplated to provide 
staggered joint segments at the nailing plates to provide strength 
irrespective of the nail plates as is known in the art. Top plates 60 are 
attached to end portions of ceiling modules 44 and along full length of 
one edge of the starter and finishing ceiling modules (not shown). Top 
plates 60 support the ceiling modules from the uppermost set of wall 
modules 46. A catwalk 169 on the center of ceiling modules may be provided 
along the center ceiling modules 44 connecting adjacent joists 154 and 158 
for conventional purposes. A plurality of joist braces 169' bridge across 
joists 154 and 158 to provide support for adjustment screw 174, if used. 
If building 40 has a central load-bearing wall, ceiling modules 44 may 
extend to that wall, otherwise each ceiling module 44 will extend between 
opposite wall modules 46, as illustrated in FIG. 1. While not illustrated 
in detail, the skilled artisan would recognize that a floor/ceiling module 
48 would incorporate a combination of components of floor module 42 and 
ceiling module 44. 
Each roof module 50 includes a upper surface member 194 supported along one 
edge 182 by an elongated horizontal support member, such as roof rafter 
184 which extends along the length of roof module 50 (FIGS. 18 and 19). A 
second roof rafter 186 is run parallel to rafter 184 the entire length of 
module 50 midway between edge 182 and an unsupported edge 188. A plurality 
of bridge struts 192 are positioned along module 50 to connect top and 
bottom ends 184 and 186. Unsupported edge 188 is braced by the edge 
support brace 197 extending the full length of the module and tied to 
joist 186 by struts 192. A plurality of braces 190, spaced along the 
length of module 50, support unsupported end of roof rafter 184 during a 
shipping mode. They are swung to a position against adjoining roof rafter 
184 when installed in building 40, as illustrated by phantom position in 
FIG. 18. Rafter 184 extends laterally beyond edge 182 in order to support 
unsupported edge 188 of the adjacent roof module. Full length top plates 
60 (now shown) are attached to the starting and finishing module to rest 
cable and module 46'' . 
Upper surface member 194, which may be made from waterproof press board, 
plywood, gypsum board or the like, and a metal clad 196 which may be 
formed with a plurality of valleys 198 to provide for channelling water 
off of the roof. The outer edges of metal clad 196 at edges 182,188 of 
each roof module are turned down at 200 and fastened to the edge of 
support panel 194 by conventional means such as by nailing or by an 
adhesive. Portions 200 of adjacent roof modules 50 are joined in a 
water-resistant fashion by a cap 202 running the length of the edge of 
adjacent roof modules, as illustrated in FIG. 19. 
An apparatus 203 to manufacture roof modules 50 includes a conveyor 205 
which transports panel 194 from right to left (FIG. 20). Attached to panel 
194 are rafters 184, 186, bridge struts 182 and 182' and brace 197. A 
spray foam is deposited at 204 on panel 194 and metal clad 136 is embossed 
by a pair of rollers 260a, 206b from a continuous strip of pre-finished 
aluminum or other metal 208 from a roll 210. The embossed metal clad 196 
is joined with support panel 194 and may be compressed by nip rollers (not 
shown) with the spray foam both adhering the surfaces together and filling 
the void between channels 198 formed in the metal clad. 
A heel bracket 212 on each roof rafter 184,186 and a pin 214 extending 
laterally from joists 154 and 158 of ceiling module 44 provides 
unidirectional support for the roof modules. Heel bracket 212 cams over 
the pin 214 as the roof module is being pulled into place, as illustrated 
by the arrows in FIG. 21. Once the heel bracket clears the pin, the pin 
engages the heel bracket to support the roof module in the position 
illustrated in FIG. 21. A goal-post shaped guide 265 is fastened to an end 
of each ceiling joist 154, 158 in the vicinity of pin 214. The purpose of 
guide 265 is to assist the movement of roof module 50 into place in order 
to reduce the number of laborers required. 
Roof modules 50 are supported at their upper ends by a ridge rafter or beam 
216. Additional support for both the roof modules and ceiling modules is 
provided by support means, generally indicated at 220. Support means 220 
includes a compression strut 222 positioned between a mid-portion of each 
roof rafter 184, 186 and the subjacent ceiling joists 154 and 158 in order 
to support roof loads. A flexible tension member, such as tension cable 
224, extends from a bracket assembly 226, supported from ridge beam 216, 
and engages at opposite ends with a strut saddle 228 attached to ceiling 
joists 154 and 158. Bracket assembly 226 includes a roof rafter end 
bracket 230, which is fastened to the end of roof rafter 184, 186 and a 
ridge beam bracket 232 which straddles ridge beam 216 (FIGS. 22 and 23). 
Rafter end bracket 230 is made from sheet metal and includes a folded 
portion 234 having a lower edge 236 which defines a support surface for 
engaging an edge 238 on a wing 240 extending laterally from ridge beam 
bracket 232, which is also formed from sheet metal. Edges 236 and 238 form 
means for supporting the end of rafter 184, 186 from the ridge beam. 
Fasteners, such as nails 258'', provide means for fastening the roofing 
modules to the beam 216. Rafter bracket 230 includes a downwardly 
extending tab 242 having an opening aligned with a tab 244 extending 
downwardly from ridge beam bracket 232 in order to provide support for 
tension cable sheath 264. 
Strut saddle 228, which is also formed from sheet metal, includes a back 
wall 246 having a raised portion 248 stamped therefrom in order to provide 
a strut locating surface for positioning compression member 222 with 
respect to joist 1564 and 158 (FIG. 24). An opening 250 in black surface 
246 engaged by an end 252 of tension cable assembly 224. Strut member 228 
additionally includes downwardly extending ears 254 which straddle ceiling 
joists 154 and 158 and are attached thereto by fasteners 258'. Tab 253 is 
formed from back wall 246 and tabs 251 are formed from ears 254 to rest on 
ceiling joist 154 and 158 at an angle that will cause strut saddle 
backwall 246 to follow the roof pitch. Each compression member 222 
includes a pair of ears 256 which are formed in parallel planar fashion to 
span roof rafters 184, 186 and openings 258 for nailing, or the like, to 
the rafters (FIGS. 25 and 26). The opposite end of compression member 222, 
which is formed from tube stock, is open in order to straddle strut 
locator 248. Tension cable assembly 224 includes an end 252 piece at each 
end thereof and suitable hardware 260 & 261 for attaching the end to a 
wire cable 262 (FIG. 27). Sheath 264 supports the wire cable over tabs 242 
and 244 to prevent fraying of the cable. Once the roof modules are 
supported in position, shims (not shown) may be inserted between the ends 
of the roof rafters and ridge beam to align roofing modules. A 
conventional ridge vent (not shown) may be applied over ridge beam 216. 
Wall modules 46 are not limited in application to exterior walls of 
building 40. Interior wall modules 46'' may be made from interior planar 
members 270a, 270b, both of which are finished according to an interior 
decorating scheme. Wall modules 46'' may be joined at a corner 266 by 
beveling the lateral edges of the modules (FIG. 28). Brackets 268a, 268b 
are adhered during manufacture to the interior surfaces of surface members 
270a, 270b by conventional adhesive. On the job site, the modules 46'' are 
joined utilizing a corner molding 272 fitted between the modules prior to 
the insertion of staples 274 into brackets 268a, 268b. In the illustrated 
embodiment, planar member 270a, 270b are gypsum board. 
A corner of an exterior wall is illustrated in FIG. 29 in which wall 
modules 46 are joined at a corner post 276. Corner post 276 may be a 
conventional four-by-four wood post with cladding 278 applied to match the 
cladding 108 of modules 46. Joining strips 280 are provided between the 
wall modules 46 and corner posts 276 for weather sealing purposes and to 
carry vertical loads. A wall module 46''' is adapted to the walls on the 
gabled end of building 40, by including a sloping upper end plate 68' 
configured to the pitch of roof modules 50 (FIG. 30). 
A windowed wall module 284 includes a conventional window assembly 286 
mounted between jamb struts 75 and a header assembly 290 (FIGS. 31 and 
32). Header assembly 290 includes a pair of beams 292 to distribute the 
weight from the superjacent ceiling/floor module or ceiling module (not 
shown) to vertical studs 294.' Beams 292 are held together with top and 
bottom end plates 68' and 70' filled with insulating foam leaving a 
horizontal passage lined with PVC tubing to define an upper horizontal 
conduit 84. A pair of jamb struts 75 with their grooved side 76 facing 
outwardly provide interface with free standing joining strip 280, or 
conduit studs 76'. Upper and lower horizontal conduits 84'' and 86 are 
provided in the same vertical location as in wall modules 46 in order to 
provide continuity of the passageway. All components are held together by 
installation of inside and outside molding strips 299 and shipping brace 
73. FIG. 35 shows planer module and window module interface with joint 
strip 280. 
A portalled wall module 298 includes a conventional prehung door 300 and 
header module 290 including beams 292 which are attached with jamb studs 
75 with grooved side 76 and supported by the frame of door 300 (FIGS. 33 
and 34). Only an upper horizontal, foamed-in, PVC-lined conduit 84 is 
allowed for the portalled wall module with the lower opening in the end 
strut being closed off by the frame of prehung door 300. Shipping brace 73 
is removed before assembly while outside and inside jamb moldings 299 are 
attached at the factory. 
It can be seen that the materials and structure of the modules provide 
reduced-weight planar modules. Accordingly, the modules can be handled by 
two workers on the Job site without requiring special equipment. The 
planar modules can be shipped securely and compactly over long distance 
economically. The unique supporting hardware for the roof and ceiling 
modules are, likewise, made of light weight materials to reduce shipping 
costs and to ease assembly effort. Because the modules may be handled by 
laborers alone and, therefore, no special job site equipment is necessary, 
conventional transportation equipments, such as common trailer trucks, may 
be used to transport the building to the job site. Because the invention 
further provides for on-site assembly without professional installers, 
eliminates the difficulty of scheduling skilled labor at the job site is 
avoided. 
The unique arrangement of planar wall modules incorporates both horizontal 
and vertical passages inside of a foam core for both electrical wiring and 
plumbing lines. Furthermore, the structure defining the passages also 
secures the interior and exterior surface panels and the upper and lower 
end plates together while providing load bearing support for superjacent 
modules. The unique module structure additionally provides for closer 
tolerance of building module assemblies than previously possible, while 
concealing many of the wall, ceiling, roof and floor joints in order to 
provide a smooth and pleasing surface at the joints. 
The materials that may be applied to the modules lend themselves to 
recycling and reduction of waste while accommodating conventional 
architectural styles in virtually any geographic location. The various 
modules are self-aligning without requiring separate fasteners, except for 
occasional locations, and liquid adhesive in order to further simplify the 
procedure at the job site and to enhance the fit and finish of the 
building. 
Changes and modifications in the specifically described embodiments can be 
carried out without departing from the principles of the invention, which 
is intended to be limited only by the scope of the appended claims, as 
interpreted according to the principles of patent law, including the 
Doctrine of Equivalents.