Patent Publication Number: US-2022235547-A1

Title: Steel and concrete building module and connections

Description:
TECHNICAL FIELD 
     This application relates to modular building units. In particular it relates to a building module with a precast concrete floor, a roof and walls, and the connections between adjacent modules. 
     BACKGROUND 
     Prefabricated modular homes, individual building units of a multi-unit complex, or portions of such can provide benefits to the housing industry as they are pre-manufactured in a controlled factory setting. This reduces production time and cost while increasing quality and efficiency compared with the labour-intensive one-specialty-at-a-time, on-site build which is often error prone and wasteful. Prebuilt units are prepared with walls and floors already housing the connections for utilities, attachments, and furnishings and they are assembled using equipment designed to cope with the particular characteristics of substantially complete structures. 
     Existing U.S. Ser. No. 10/947,716 to Bowron describes differing aspects of a prefabricated multi-unit project such as a specialized connector assembly. This has a corner block, gusset plate, hallway, and pre-determined grid, which provides a compact, load-bearing, moment-connected complete system for assembling module frames so as to quickly rig and hoist entire modules, connect the modules, and form buildings. 
     In another case, U.S. Ser. No. 10/584,484 to Cohen has structurally supportive steel wall trusses stacked vertically with their mated tube steel frames interconnected in three dimensions. It also has concrete floors, which are supported and continuous throughout the level, dropped in place and additionally poured. Both contain utilities, a prefabricated kitchen, and other elements within their structure. 
     A third system disclosed in U.S. Ser. No. 10/145,103 by Collins describes the assembly of multiple prefabricated parts such as non-weight-bearing walls containing interior components and exterior fixtures, structural steel perimeter framing, vertical slabs, cast-in-place concrete, stairs, and elevator using unskilled labour, additionally incorporating recycled materials, solar panels, and water collection. 
     This background is not intended, nor should be construed, to constitute prior art against the present invention. 
     SUMMARY OF INVENTION 
     The presently disclosed modular building systems are modular units constructed using precast concrete to build residential, commercial and multi-use buildings. The focus is on simplifying the construction of the modules and the connections between the modules and other elements. 
     Using the modular system may reduce the construction budget and the construction schedule and improve the final product quality. It reduces the exposure of the building during construction to severe weather conditions, and will reduce on-site human error. Finally, it will help to reduce the errors and omissions between professional design drawings and contractors&#39; shop drawings, and conflicts, as the modular unit drawings are a combination of both, and have relatively more detail and coordination. 
     While some construction materials and methods are known in the art, translating common on-site engineering techniques to their particular usage when dealing with prefabricated modular buildings requires several unique and specific considerations 
     Disclosed is a building module comprising a precast concrete floor with opposing edges thickened below the floor, a frame comprising hollow structural section bars attached to a top surface of the precast concrete floor over the thickened edges, and a roof attached to the frame. 
     Also disclosed is a building comprising a building module that comprises a precast concrete floor with opposing edges thickened below the floor a frame comprising hollow structural section bars attached to a top surface of the precast concrete floor over the thickened edges, and a roof attached to the frame. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  shows an exterior wall at the mid-span of a module, according to an embodiment of the present invention. 
         FIG. 2  shows an exterior wall parallel to span columns, according to an embodiment of the present invention. 
         FIG. 3  shows an interior party wall connection seen parallel, according to an embodiment of the present invention. 
         FIG. 4  shows an interior party wall connection seen perpendicular, according to an embodiment of the present invention. 
         FIG. 5  shows a module to module connection, according to an embodiment of the present invention. 
         FIG. 6  shows a module to module end wall bearing, according to an embodiment of the present invention. 
         FIG. 7  shows a module to module alignment pin, according to an embodiment of the present invention. 
         FIG. 8  shows a typical panel to panel connection, according to an embodiment of the present invention. 
         FIG. 9  shows a typical corridor floor connection, according to an embodiment of the present invention. 
         FIG. 10  shows a corridor floor connection at lobby, according to an embodiment of the present invention. 
         FIG. 11  shows a typical corridor HSS end plate, according to an embodiment of the present invention. 
         FIG. 12  shows a plan view of an alternate HSS end plate at a corner, according to an embodiment of the present invention. 
         FIG. 13  shows the elevation of the alternate HSS end plate at the corner, according to an embodiment of the present invention. 
         FIG. 14  shows a slab transition, according to an embodiment of the present invention. 
         FIG. 15  shows a module beam at an elevator corner, according to an embodiment of the present invention. 
         FIG. 16  shows a column beside an elevator shaft, according to an embodiment of the present invention. 
         FIG. 17  shows a second view of the column beside the elevator shaft, according to an embodiment of the present invention. 
         FIG. 18  shows a modules on a pilaster, according to an embodiment of the present invention. 
         FIG. 19  shows a plan view of  FIG. 18 , according to an embodiment of the present invention. 
         FIG. 20  shows a section of an architectural plan showing four modules, according to an embodiment of the present invention. 
         FIG. 21  shows columns at module interiors, according to an embodiment of the present invention. 
         FIG. 22  shows a parapet extension splice, according to an embodiment of the present invention. 
         FIG. 23  shows a roof deck parallel to span, according to an embodiment of the present invention. 
         FIG. 24  shows an elevator header panel at a lobby, according to an embodiment of the present invention. 
         FIG. 25  shows a porte cochere column cap connection, according to an embodiment of the present invention. 
         FIG. 26  shows a concrete module beam at an elevator lobby, according to an embodiment of the present invention. 
         FIG. 27  shows an infill panel at elevator doors, according to an embodiment of the present invention. 
         FIG. 28  shows a module exterior end wall, according to an embodiment of the present invention. 
         FIG. 29  shows a connection at pilaster, according to an embodiment of the present invention. 
         FIG. 30  shows an interior pile, according to an embodiment of the present invention. 
         FIG. 31  shows an elevator pit, according to an embodiment of the present invention. 
         FIG. 32  shows a module to module connection, according to an embodiment of the present invention. 
         FIG. 33  shows an exterior wall viewed parallel to span at a column, according to an embodiment of the present invention. 
         FIG. 34  shows an interior party wall connection viewed perpendicular, according to an embodiment of the present invention. 
         FIG. 35  shows a typical corridor connection, according to an embodiment of the present invention. 
         FIG. 36  shows an interior party wall connection over beams, according to an embodiment of the present invention. 
         FIG. 37  shows an interior party wall connection viewed parallel, according to an embodiment of the present invention. 
         FIG. 38  shows an exterior wall at mid-span, according to an embodiment of the present invention. 
         FIG. 39  shows a module to elevator panel, according to an embodiment of the present invention. 
         FIG. 40  shows an elevator wall at mid-span, according to an embodiment of the present invention. 
         FIG. 41  shows a typical corridor HSS plate, according to an embodiment of the present invention. 
         FIG. 42  shows an elevator header panel, according to an embodiment of the present invention. 
         FIG. 43  shows a beam inside the elevator, according to an embodiment of the present invention. 
         FIG. 44  shows a slab transition, according to an embodiment of the present invention. 
         FIG. 45  shows a floor steel corridor span, according to an embodiment of the present invention. 
         FIG. 46  shows a roof at high parapet, according to an embodiment of the present invention. 
         FIG. 47  is a schematic perspective view of a module, according to an embodiment of the present invention. 
         FIG. 48  is a perspective view of the frame and floor of a module, according to an embodiment of the present invention. 
         FIGS. 49-56  are examples of embedded components, according to an embodiment of the present invention. 
         FIG. 57  is a perspective view of a module floor that is extended at one end, according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION 
     A. Glossary 
     HSS—Hollow Structural Section 
     PSA—Pipe Sleeve Anchor 
     ID—Internal diameter 
     B. Item List 
     
         
           6 ,  7 ,  8 ,  9 ,  10 ,  11 ,  16 ,  17 . Precast wall panel for the building exterior. 
           12 ,  15 ,  18 . Precast inner layer of exterior wall panel. 
           13 . Precast outer layer of exterior wall panel. 
           14 . Insulation layer of exterior wall panel. 
           20 . Rolled rod to fit gap complete with foam backer rod and sealant. 
           21 . Rolled rod. 
           30 ,  31 ,  32 ,  33 ,  34 ,  35 ,  36 ,  37 . Embedded components. 
           40 . Precast floor panel. 
           41 . Thickened edges of precast floor panel. 
           42 . Inner portion of floor panel. 
           43 . End surface of the floor panel. 
           44 . End surface of thickened floor edge. 
           45 . Roof. 
           46 . Roof support fitting. 
           47 . End of floor. 
           50 . ¼″×4″ wide steel plate. 
           60 . Elastomeric bearing pad typical over column caps. 
           61 ,  62 ,  63 . Columns. 
           64 . Column cap. 
           65 ,  66 ,  67 . Party wall. 
           68 . Beam. 
           69 . Column. 
           70 . Precast module end floor region. 
           80 ,  81 ,  82 ,  83 ,  84 . Precast module end wall. 
           90 . Module end wall. 
           92 . Side wall of module. 
           100 . Pin void cast into wall panel. 
           110 . 1″ dia. cold rolled steel pin. 
           120 . Foam backer rod and sealant to suit. 
           130 . 16″×16″×½″ steel plate complete with 3½″ long A325 bolts. 
           140 . Embed plates cast into the floor. 
           141 . Embedded plate. 
           150 . Grout fill ⅜″×6″ recess typical at all accessible floor joint locations. 
           160 . HSS beam. 
           170 . L6″×4″× 5/16″×14″ long steel angle complete with ⅝″ dia.×3½″ long A325 bolts to align with outermost holes. 
           180 ,  181 . Module columns, beyond. 
           190 . 12″×4″×½″ steel plate complete with ⅝″ dia. HUS™ bolts. 
           200 . 8″×4″×½″ steel plate to end of floor beam. 
           210 . End of floor beam. 
           220 . 5½″×4″×½″ steel plate complete with ⅝″ dia. HILTI HUS™ anchor. 
           225 . Insulation. 
           230 . 8″×16″×½″ steel plate complete with ⅝″ dia.×3½″ long A325 bolts. 
           235 . T-section plate. 
           240 . Module to module embed plates cast into module floors connection across corridor modules. 
           250 ,  251 ,  252 ,  253 ,  254 ,  255 ,  256 ,  257 ,  258 . Module. 
           260 . 8½″×3″×⅜″ steel plate. 
           270 . Elevator shaft wall. 
           280 . Precast elevator wall. 
           290 . 1⅛″ I/D sleeves through precast floor beam complete with 1″ dia. steel rod and adhesive. 
           300 . Cast in place concrete pilaster. 
           310 . Cast in place elevator foundation wall. 
           320 . Line of pilaster below. 
           330 . Line of pier below. 
           340 . PSA embeds. 
           350 . Precast header panel. 
           360 . L6″×4″×⅜″ continuous steel angle. 
           370 . Precast column cap. 
           380 . Precast elevator lobby floor. 
           390 . Cast in place concrete wall. 
           391 . Rebar. 
           392 . Dowel. 
           400 . Standard grout can through panels complete with 10M dowels. Drill into foundation wall 6″ embedment complete with adhesive. 
           410 . Infill precast concrete wall. 
           420 . Embed in foundation wall to match embeds in precast wall. 
           430 . 2″ rigs insulation. 
           440 . Grade beam. 
           441 . Rebar. 
           450 . 4″ void from typical between piles. 
           460 . 10M dowels at 48″ drill 6″ into the foundation wall complete with adhesive. 
           470 . All exterior concrete to slope min 2% away from building. 
           480 . Horizontal bent down through thickening. 
           490 . Edge thickening. 
           500 . Pier. 
           510 . Pile complete with pile cap. 
           511 . Pile cap. 
           520 . Grout fill ⅜″×6″ recess. 
           530 . 16″×16″×½″ steel plate complete with ¾″ dia. bolts. 
           531 ,  532 . Rebar. 
           540 . Embeds at 48″, ⅝″ dia. shear studs, 5″ embedment. 
           550 . Precast to precast connection. 
           560 . ¼″0 ×4″ steel plate at 48″. 
           570 . 12″×6″×½″ steel plate complete with 5′8″ dia. HUS™ bolts. 
           575 . Beam. 
           580 . Floor slab. 
           590 . 8″×16″×½″ steel plate complete with ⅝″ dia.×3½″ long A325 bolts. 
           600 . Module to module embedded plates cast into module floors, connection across corridor modules. 
           610 . L6″×4″× 5/16″×14″ long steel angle complete with ⅝″ dia.×3½″ long A325 bolts to align with outermost holes. 
           620 . Precast panel to panel connection at 48″. 
           720 . HSS frame. 
           721 . Horizontal HSS frame members. 
           722 . Vertical HSS frame members. 
           723 . Footings for columns. 
           724 . Studding. 
           734 . End of embed. 
           736 . Embed opening for bolt. 
           738 . Embed loop. 
           758 . Embed plate. 
           774 . Extension of floor. 
           800 ,  801 ,  802 ,  803 . Modules. 
           804 ,  805 ,  806 ,  807 . Floor extensions. 
       
    
     C. Module 
     Individual modules, stacked vertically and horizontally, form a building. There are apartment, elevator, stairs, lobby, restaurant, fitness and spa, laundry facility, roof, and port cochere modules, to name a few. Apartment modules can be simply lined up like a parking lot and stacked or adapted to other more interesting configurations or designs, and the modules can be joined to form multiple room living units as well as extended spaces such as in a lobby, event room, or indoor parking. The modules may have appendages for balconies and hallways. 
     The modules are prefabricated to include the walls, floor, concrete slabs (wall and floor), insulation, utilities (electrical wiring, water pipes, ducts, heating and air conditioning units), wall and floor finishings (surface treatments and features including plaster, paint, carpet, tile, switches), and furnishings for the different rooms including built-in bathroom faucets, toilets, shower/bath, kitchen counters, cabinets, appliances, light fixtures, and moveable chairs, tables, and beds. 
     The modules are pre-manufactured for their own structural integrity and are built to fit together, laterally and vertically stacked, to support the structural integrity of the entire multi-module building through their load-bearing points. The concrete slab floors and three-dimensional frame formed from bolted columns and roof beams (HSS columns and beams) are load-bearing across the module structure, and the thickened slab edges align with the beams to bear the vertical structural load through the building, cushioned by elastomeric bearing pads. 
     Furthermore, each module is assembled in a factory and has a roof for weather protection. 
     The building modules  250 ,  251  are shown in  FIG. 6 . Each module  250 ,  251  has a module end wall  90 . The end wall  90  may be an exterior end wall or an interior end wall. One module  250  is placed above another module  251 . The upper module  250  rests on elastomeric bearing pads  60  on the lower module  251 . Likewise, the lower module  251  is supported by elastomeric bearing pads  60 . These lower bearing pads may in turn be supported by foundations, beams or other modules. 
     Another view of a module  250  is shown schematically in  FIG. 47 , showing the module to have a generally cuboid shape or envelope. The module  250  has a precast concrete floor  40 , with thickened edges  41  running the whole of the length (i.e. span) of the module. The inner portion  42  of the floor is thinner than the edges  41 . The ends  43  of the floor are not thickened, at least in the middle, but may be thickened at their extremities  44  as a result of the thickening of the edges of the floor. The module  250  has end walls  90  at opposite ends of the module, and side walls  92  on opposite sides of the module. One of the side walls  92  may be an exterior wall, or both side walls may be interior, or party walls. A roof  45  is present on the top of the module, the roof being corrugated, for example. The roof  45  is welded to the top perimeter of the frame, which is made of steel. The attached roof provides additional structural strength and rigidity to the module. 
       FIG. 48  shows the HSS frame  720  of a module  250 . The frame has horizontal members  721  that provide rigidity to the tops of the module walls and support for the module above, if any. Additional horizontal members may connect the longer horizontal members across the width of the module. The frame  720  also has vertical members  722  that form columns to support the upper portions of the frame and transmit the load from a module above to the floor  40 . The columns are welded to footings  723  that are screwed or bolted into the floor  40 . The footings are attached to the thickened edges  41  of the floor. Studding  724 , such as aluminum studding, is installed between the upper, horizontal members  721  of the frame and the concrete floor  40 , and may be present in multiple walls of the module. Interior room walls, e.g. drywalls, are attached to the studding on the inside of the module, and finished. Exterior walls, which may be building exterior walls or walls on the outside of the module that are interior to the building, are attached to the frame  720 , the edges or ends of the floor  40 , or both the frame and the floor. Gaps in the studding may be left for windows and doors. 
       FIG. 2  shows an upper module  251 , with precast concrete floor  40  and precast exterior wall panel  11 , located over a lower module  250  with precast exterior wall  10 . The upper module  251  is supported by an elastomeric bearing pad  60  located between a column  61  of the lower module and the bottom of the floor panel  40  of the upper module. The bearing pad  60  is mounted on top of a column cap  64  on top of the column  61 . Column  62  of the upper module  251  is screwed to the floor  40  of the upper module. Columns  61 ,  62  are made from HSS and form part of the frame  720  that provides structural strength to the module. Columns  61 ,  62  may be referred to as span columns, as they support the span of the modules with other span columns. 
     Still referring to  FIG. 2 , the precast exterior wall panels  10 ,  11  are building exterior walls. They have a layered structure, with precast concrete inner layer  12  and precast concrete outer layer  13 , with an insulation layer  14  sandwiched between them. It will be clear that other building exterior wall structures may be employed in other embodiments. 
       FIGS. 3 and 33  also show the elastomeric bearing pads  60  between modules that are located one above the other. 
     Referring to  FIG. 20 , four modules  800 ,  801 ,  802 ,  803  are shown connected to each other on a floor of the building. A corridor is formed by extensions  804 ,  805 ,  806 ,  807  to the module floors. 
     D. Floor 
     Referring to  FIG. 47 , the floor  40  of a module is precast concrete. The floor is typically rectangular, with the long sides referred to as edges and the shorter sides referred to as ends. The floor is thicker at the edges  41  compared to the inner portion of the floor. The thickened edges may extend the full length of the edge, or partially along the edge. 
     Referring to  FIG. 57 , the thinner, inner portion  42  of the floor may in some cases extend in length beyond the end faces  44  of the thickened edges  41 , or the thickened edges terminate before reaching a given end  47  of the floor. This results in an extension  774  of the inner floor area, which is of lower thickness than the edges, to form the floor or partial floor of a corridor that is outside the room defined by the walls of the module. In other embodiments, the extended floor area  774  beyond the thickened edges  41  may serve as a balcony. Note that in some embodiments, the shape of the floor may be square. Two such modules positioned as mirror images may be connected with their extensions  774  abutting each other, to form the floor of a corridor, as in  FIG. 20 . 
     Adjacent modules  251  may be aligned with their thickened floor edges  41  alongside each other, as in  FIG. 3 . The thickened edges  41  of the floors  40  rest on elastomeric bearing pads  60 , which are located on columns  61  of the modules  250  below. Other columns  62  are bolted to the top surface of the floors  40 . Also shown in this figure are the roofs  45  of the lower modules  250 , which are supported by fittings  46  attached to the upper region of the columns  61 . 
       FIG. 5  shows the end portion  70  of the floor  40 , i.e. the precast module end floor  70 , which extends to the end  43  of the floor.  FIG. 39  also shows a sectional view taken through the thinner, inner portion  42  of the floor away from the edges, showing the inner portion of the floor being thinner than the edge  41  of the floor. 
     E. Exterior Wall Connection 
     The exterior wall connections are shown in  FIGS. 1, 2, 28, 33 and 38 . These walls are those that are on the exterior of the building. 
     Referring to  FIG. 1 , which is at mid-span of the modules, each exterior wall  10 ,  11  is a precast concrete wall panel. The panel  10 ,  11  has two outer precast concrete layers  12 ,  13  and an inner layer  14 . The outer portion of the exterior precast wall panel  10 ,  11  may have an embed  30  located at the mid-span of the module. Both upper and lower exterior precast wall panels  11 ,  10  respectively have an embed  30  at the mid-span. An example of such an embed may be seen in  FIG. 53 . The outer portions  13  of the exterior precast wall panels  10 ,  11  are connected to each other via a combination  20  of a rolled rod, backer rod and sealant. 
       FIG. 1  shows one building module  251  located above another building module  250 , at a position mid-span along a longer side of the modules. Each module  250 ,  251  has a non-load-bearing precast exterior wall panel  10 ,  11  that is a sandwich of concrete panels  12 ,  13  filled with insulating material  14 . Each exterior wall panel  10 ,  11  is strengthened with an embedded rod  30 . The embeds  30  have a steel plate  758  that is present on the lower edge of the outer concrete portion  13  of the upper exterior wall  11 , and the upper edge of the outer concrete portion of the lower exterior wall  10 . Sealing connections between the exterior walls of the vertically placed modules at mid-span are made with a rolled rod  20  dimensioned to fit the gap between the steel plates  758  in the outer concrete panels of the upper and lower exterior walls. Sealing continues between the lower edge of the outer concrete portion  13  of the upper exterior wall  11 , and the upper edge of the outer concrete portion of the lower exterior wall  10  where plates  758  are not present. A ¼″×4″ wide steel plate  50  is present on the top edge of the inner precast concrete layer  15  of the lower exterior wall panel  10 . The inner precast concrete layer  15  is lower in height than the insulation and outer concrete layers. This allows for sealant to be added from the inside of the module and for fireproofing to be installed. Embedded component  32  is cast into the inner concrete layer  15  of the lower panel  10 . A precast floor  40  is thickened at its edge  41  where the floor and the inner surface of the exterior wall panel  11  meet. 
     Rigid load-bearing prefabricated frames of primarily concrete and steel generally conduct vibration throughout the structure including that of seismic activity, incurring stress, and even more so for the stronger precast slabs made off-site. Referring to  FIG. 2 , to absorb and dampen unwanted vibration, elastomeric bearing pads  60  typically are placed over column caps  64  between the supporting column  61  and the thickened edge  41  of the precast floor  40  adjacent to the exterior wall  11 . 
       FIG. 2  shows the upper and lower precast exterior wall panels  11 ,  10  respectively alongside the columns  62 ,  61 . In contrast to the view of  FIG. 1 , the upper and lower precast exterior wall panels  11 ,  10  may not have embeds  30  at this location.  FIG. 28  shows a precast exterior wall panel  84  on a grade beam  440  that forms a foundation wall. The grade beam is reinforced with rebar  441 . Embeds  420  are present in the foundation wall to match the embeds in the precast exterior wall panel  84 . 
       FIG. 28  is a diagram at the exterior end wall  84  of the module  250  where the precast module wall extends down to the foundation wall  440  and is secured across the gap with embedded components  420  in both. The foundation wall includes a grade beam  440  and is insulated to its side by 2″ rigs insulation  430  and protected from below by a 4″ void typical between piles  450 . 
       FIG. 33  shows the precast exterior wall panel  17 ,  16  at the columns. Both upper and lower exterior precast wall panels  16 ,  17  respectively have an embed  33  by the columns.  FIG. 33  displays the connection of exterior walls  17 ,  16  adjacent to the span at the location of the columns  61 ,  62 . The precast module floor  40  sits on an elastomeric bearing pad  60  over the column cap of the module beneath, directly below and in line with the upper column which is bolted into the module floor slab. The weight-bearing columns of the upper and lower modules align vertically and parallel to the exterior wall. Inside the precast exterior wall panel  17 ,  16  the connection of upper and lower modules uses embedded metal rods  33  at top and bottom of the panels and sealant across the gap. 
       FIG. 38  shows the exterior precast wall panels  17 ,  16  at the mid-span, of modules  252 ,  253  respectively. There is a precast to precast connection  550  between the upper and lower precast exterior wall panels  16 ,  17  respectively. Embeds  33  are present in the outer layers of the precast wall panels  17 ,  16 . Such embeds may be seen in  FIG. 55 , for example. 
       FIG. 38  shows the exterior wall adjacent to mid-span of the modules  252 ,  253 , where a precast to precast connection  550  joins upper and lower modules  253 ,  252  by way of opposing embedded metal rod and plate assemblies  33  where the precast wall panels  252 ,  253  meet at the exterior facade. At the interior layer of the lower wall panel, ¼″×4″ steel plates  560  at 48″ (1.2 m) spacing connect to the lower module beam  721 . As modules  252 ,  253  are stacked, the lower module beam will support the upper module floor at its thickened outer edge  41 . 
     F. Interior Wall Connection 
     The interior wall connections are shown in  FIGS. 3, 4, 34 and 36 . 
       FIGS. 3 and 4  display the interior walls between modules with the columns  62  of the HSS load-bearing steel frame bolted into the slabs  40 . 
       FIG. 3  shows an interior party wall connection, in which the thickened edges of the floor panels  40  are positioned alongside each other. The columns  62  above the floors are alongside each other, and the columns  61  supporting the floors are alongside each other. The columns  61 ,  62  are embedded in the party walls  65 ,  66  between the adjacent modules.  FIG. 4  is a view in a direction perpendicular to that seen in  FIG. 3 .  FIG. 34  shows another view of a connection in an interior party wall.  FIG. 36  shows another view of a an interior party wall  67  over adjacent floors  40 , where the thickened edges  41  of the adjacent modules are supported by beams  68 . 
       FIG. 34  is a view of interior party wall face-on. Where the in-line vertical load-bearing columns  62  of the upper module meet the floor  40 , the upper module column is bolted through the thickened edge  41  of its precast slab floor. The lower module column  61  is capped with an elastomeric bearing pad  60  beneath the upper floor slab edge  41 . 
       FIG. 36  is a view of the interior party wall connection to supporting horizontal beams  68 . The modules meet each other at their thickened ends  41  with the load of the stacked building modules supported vertically through each module column  61  bolted into its concrete floor slab  40 . The load continues downward through the concrete ends onto underlying supports  68 . 
       FIG. 37  shows where two modules  250  meet at the precast module floor slab edges  41 . The edges  41  rest on elastomeric bearing pads  60  found typically over horizontal supporting beams  721  beneath. The horizontal supporting beams  721  are reinforced at the module meeting point by embeds at 48″ spacing, which are ⅝″ diameter shear studs  540  cast in the concrete, and a 5″ depth. 
     G. Module Connection 
     Modules are connected to each other as shown in  FIGS. 5, 6, 7 and 32 . 
       FIG. 5  shows an upper module  255 , with precast exterior end wall  80  and precast end region  70  of the floor  40 . The upper module  255  is placed over a lower module  256  that has a precast exterior wall panel  17 . The connection between the bottom of the precast end wall  80  and the top surface of the outer panel of the precast exterior wall  17  is made with a combination  20  of a rolled rod, backer rod and sealant. Embeds  30  are present in the outer layers of the exterior end wall  80  and exterior end wall  17 .  FIG. 5  also shows the precast floor end region  70  at the end of the module  255  inserted into a cut-out of the inner concrete layer  18  of the precast wall  80 . In this view the corrugated roof  45  is more readily visible. 
       FIG. 6  shows one module  250  placed above another module  251 . The upper module rests on elastomeric bearing pads  60  on the lower module. The modules are aligned vertically, not staggered, so the supportive steel frames of the modules line up vertically. 
       FIG. 7  shows an upper module  257 , with precast end floor  70  and precast end wall  81 , located over a lower module  258  that has a precast end wall  82  and embed  30 . There is a pin void  100  cast into the lower surface of the outer portion of the precast end wall  81  of the upper module  257 . A cold rolled steel alignment pin  110  is present in the top surface of the outer portion of the precast end wall  82  of the lower module  258 . The pin void  100  receives the alignment pin  110 . In other embodiments, other locating techniques may be used. For example, the void may be in the top surface of the lower end wall, and a pin may project down from the bottom surface of the upper end wall. 
       FIG. 32  shows an upper module, with precast end floor  70  and precast end wall  83 , located over a lower module that has a precast end wall  84 . Both precast end walls  83 ,  84  have embeds  30 . The connection between the bottom of the outer portion of the precast end wall  83  and the top surface of the outer portion of the precast end wall  84  is made with a combination  20  of a rolled rod, backer rod and sealant. Attached to the lower end wall is a metal angle which supports the lower module ceiling  45 . 
     H. Panel Connections 
     The panel connections are shown in  FIG. 8 . These connections are similar to the ones shown in  FIG. 1 . Two exterior precast wall panels  10  are shown side by side. They are connected with a rolled rod  21  to fit the gap. A foam backer rod and sealant to suit  120  are also placed in the gap. Reinforcing embeds  30  are included in the outer layers of the wall panels. 
     I. Floor Connections 
     Floor connections are shown in  FIGS. 9, 10, 11, 14, 35, 44 and 45 . 
       FIG. 9  shows a corridor floor connection. A steel plate  130  connects two adjacent, extension portions  774  of the floors  40  of the modules to either side of the corridor. The extension portions  774  form the corridor floor. Each portion of the corridor floor has plates  140  cast in place, to which the steel plate  130  is connected using bolts. In a typical concrete slab corridor connection, 3½″ long A325 bolts from an attached 16″×16″×½″ steel plate  130  bolt into the bolt voids of embedded components  140  cast into the slab floor. The embedded components  140  may similar to those in  FIG. 50 , where the end  734  is welded to plate  141 . Opening  736  is exposed for the insertion of a bolt. Loop  738  extends into the thickness of the floor to hold the embed in place. Grout  150  fills the gap between the floor extensions  774  and helps to smooth out any step that may be present due to the different heights of the upper surfaces of the floor extensions. 
       FIG. 10  shows a corridor floor connection at the lobby. A steel angle plate  170  connects two adjacent portions of the corridor floor. Each portion of the corridor floor has plates cast in place, as in  FIG. 9 , to which the steel angle plate  170  is connected. Grout  150  fills the gap and levels the floor. Beam  160  connects the floor panels of the two modules that are on opposing sides of the corridor floor connection. At the lobby, for example, the corridor floor connection is supported with an underlying HSS beam  160  spanning the length between modules and bolted into the concrete floor slabs on either side. A 6″ length×4″× 5/16″×14″ long steel angle plate  170  complete with ⅝″ diameter×3½″ long A325 bolts which align with the outermost holes of the embedded components  140  attaches to the HSS beam. Grout  150  fills the 3/16″×6″ recess typical at all accessible floor joint locations. 
       FIG. 11  shows a typical corridor HSS end plate. The floors  40  of two adjacent modules are connected with plate  190  at the ends of the thickened edges  41  of the floor, below the upper, thinner portion  42  of the floor. An HSS beam  160  is welded to and projects outwards from the plate  190 . Columns  62  of the modules are shown connected to the floors  40  of the modules. Under a typical corridor floor, the HSS beam terminates with a 12″×4″×½″ steel plate  190  complete with ⅝″ diameter bolts that are bolted into the concrete floor. The module columns  62 ,  69  in the figure are located beyond the corridor, belonging to the modules from which the corridor floor portions extend. 
       FIG. 14  shows a slab transition with a T-section plate  235  between the end floors  70  of two adjacent modules. A steel plate  230  is connected with bolts to module-to-module embed plate  240  cast into the floor. Where the slabs transition one to another an 8″×16″×½″ steel plate  230  complete with ⅝″ diameter×3½″ length A325 bolts is connected to the slab end into module to module embed plates  240  with bolt voids cast into the module floors for connection across the corridor modules. 
       FIG. 35  shows another typical corridor connection. A steel plate  530  is connected with bolts to embeds  140  in the adjacent floors either side of the connection. Grout  520  fills the recesses on each side of the join and the gap between the join. The two floor slabs are joined at their unthickened, extended ends  47  with embedded plates  141  and connector plate  530 . The embedded components have shafts which accept ¾″ diameter bolts that pass through an attached 16″×16″×½″ steel plate  530 . 
       FIG. 44  shows a slab transition between the end floors  70  of two adjacent modules. A steel plate  590  is connected with bolts to module-to-module embed plate  600  cast into the floor.  FIG. 44  details the transition between two precast module floor slab ends  70 , one thickened at its edge and the other unthickened at its edge. Module to module embedded plates are cast into both, connecting across the corridor module floors  600  from atop and between both slabs, and beneath only the unthickened slab where embedded bolt shafts in the embedded component receive ⅝″ diameter×3½″ length A325 bolts attached to an 8″×16″×½″ steel plate  590 . 
       FIG. 45  shows a steel span beneath a corridor floor. HSS beam  160  extends underneath the floor slab  580 . The beam  160  is connected to a precast header panel  350  to the right of the floor slab  580 . The two adjacent portions of the corridor floor are connected with a steel angle plate  610 . The recesses typical at the floor joint location are filled with grout  150 .  FIG. 45  displays a corridor connection of a floor slab  580  and an extension  774  of a floor  40  of a module  250 , both of which are supported by a horizontal HSS beam  160  along the entire width of the corridor. At each end, the HSS beam  160  is bolted into concrete slabs, on one end being the precast header panel  350 , and on the other end being the thickened edge  41  of the floor  40  of the module  250 . The corridor slabs join by a 6″ length×4″× 5/16″×14″ long steel angle plate complete with two ⅝″ diameter×3½″ long A325 bolts passing through angle plate holes. The accessible floor joint ⅜″×6″ recesses are filled with grout  150 . 
     J. HSS Connections 
     HSS connections are shown in  FIGS. 12, 13 and 41 . 
       FIG. 12  shows an HSS at a corner, in plan. Steel plate  200  is connected to the end of the floor beam  210 . Steel plate  220  is connected to steel plate  200 . In this alternate HSS end plate corner plan the HSS beam  160  ends at the corner in an 8″×4″×½″ steel end plate  200  attached to the beam at the end of the floor  210 . Insulation blocks  225  are shown on the inside of the corner. In line with the HSS beam  160  another 5½″×4″×½″ steel plate  220  complete with a ⅝″ diameter HILTI HUS™ anchor is fixed to the concrete slab. 
       FIG. 13  shows the alternate HSS corner end plate assembly of  FIG. 12 , from the side. The HSS beam  160  is centred under the gap between the concrete floor slabs on either side and its steel end plates are in line with the module columns  180 ,  181  beyond, belonging to the right-hand modules. 
       FIG. 41  shows a typical corridor HSS connected to a plate. The steel plate  570 , from which HSS beam  160  extends, connects the floors of two adjacent modules. The adjacent thickened edges  41  of the connected floors are supported by a beam  575  and elastomeric bearing pads. The thickened ends  41  of two concrete floor slabs are joined by a 12″×6″×½″ steel plate  570  complete with ⅝″ diameter HUS™ bolts. The module slabs are supported by horizontal beams running along both planar axes under the floor. 
     K. Elevator Core Connections 
     Elevator core connections are shown in  FIGS. 15, 16, 17, 24, 26, 27, 31, 39, 40, 42 and 43 . 
       FIG. 15  shows a module beam at an elevator corner. The floor of a module  250  is connected to an elevator shaft wall  270  with a steel plate  260  that is connected to embeds  34  in the floor and the shaft wall. 
       FIG. 16  is a view of a column beside an elevator shaft. A concrete cast-in-place pilaster  300  supports the precast floor panel  40  of a module and a precast elevator wall  280 . A sleeve  290  passes through the precast floor beam, complete with a steel rod and adhesive. 
       FIG. 17  is a plan view of the column  63  beside the elevator shaft. The outline  320  of the pilaster  300  below the precast floor panel  40  is shown. Two sleeves  290  pass through the precast floor panel, complete with a steel rod and adhesive. The cast-in-place elevator foundation wall  310  is also shown. The pilaster column  300  has 1⅛″ ID sleeves  290  which penetrate through the precast floor beam of the floor panel with a 1″ diameter steel rod and adhesive. The elevator foundation wall  310  is cast in place. 
       FIG. 24  shows the precast elevator header panel  350  at the lobby. The elevator panel  350  is connected to the precast floor panel  40  of a module using a continuous steel angle plate  360 . The continuous steel angle plate  360  is connected to embeds  35  in the header panel and the floor panel of module. Where the elevator meets each floor the module attaches to the precast elevator lobby header panel  350  via a 6″ length×4″×3/8″ continuous steel angle  360  bolted into the precast slabs with steel bolts. 
       FIG. 26  is a module beam at the elevator lobby. The precast floor panel  40  is shown adjacent to a precast elevator lobby floor  380 , the two being connected with a rolled rod  20  to fit the gap, complete with foam backer rod and sealant. Embeds  36  are shown in the precast floor panel  40  and the elevator lobby floor  380 . 
       FIG. 27  shows infill panels at elevator doors. A precast concrete floor panel  40  and an infill precast concrete wall  410  are shown above a cast-in-place concrete wall  390 . Dowels  392  pass through the infill wall  410  and into the cast-in-place wall  390 , which is strengthened by rebar  391 . Grout  400  is added around the dowels. The space beneath the precast floor slab  400  around the elevator wall  390  contains a type of fill. 
       FIG. 31  shows an elevator pit between two modules  250 . The floors  40  of the modules  250  are supported on the walls of the elevator pit. These walls are supported on elastomeric bearing pads  60  that are on the top of the walls of the elevator pit. The floor of the elevator pit has rebar  532 . The walls of the elevator pit have rebar  531 . 
       FIG. 39  shows a module adjacent to an elevator panel, which is a precast elevator wall  280 . Metal embeds  37  in the precast elevator wall  280  are used to attach a bracket  46  for supporting the roof  45 . 
       FIG. 40  shows an elevator wall at mid-span. Elevator walls  270  are precast. The floor  40  of the module is supported by an elastomeric bearing pad  60 . The precast wall panels  270  of the elevator core are solid concrete, unlike module exterior walls, but stacked the same from floor to floor. Where the precast module floor at its thickened end meets the elevator wall panel the floor end will sit on an elastomeric bearing pad  60  over the horizontal supporting column beneath. 
       FIG. 42  shows an elevator header panel. The precast header panel  350  is connected to the floor slab  580  with a continuous steel angle  360 . The steel angel  360  is connected to embeds  30  in the header panel  350  and the floor slab  580 . The floor and vertical header are joined with a 6″ length×4″×3/8″ continuous steel right angle  360  in the inner corner connected to a plate with two metal rods embedded  30  into each of the floor and header slabs of concrete. 
       FIG. 43  shows a beam inside the elevator shaft. The beam spans the gap between a column and an elevator shaft wall.  FIG. 43  shows a wider view of  FIG. 42 , showing its placement with respect to the elevator core. The precast header panel  350  supports and is in line with a vertical beam on one side of the elevator core while a horizontal beam spans the entire core to the far core wall and attaches to the far wall with an embedded metal plate and two rods  30  into the concrete slab. The far elevator wall supports a module ceiling  45  with another embedded metal plate  30  with two rods. 
     L. Column Connections 
     Columns connections are shown in  FIGS. 18, 19, 21, 25, 29 and 30   
       FIG. 18  is a view of two columns  62 . The columns are connected to the upper surface of the thickened portions of the floor panels  40  of two adjacent modules. The edges of the bases of the columns are flush with or close to the edges of the floors  40 . The thickened edges of the floor panels  40  of two adjacent modules are mounted on a pilaster  300 . A precast elevator wall  280  is shown above the floors  40  of the modules. A sleeve  290 , complete with a steel rod and adhesive, passes through the thickened portion of the precast floor panel  40  and into the pilaster  300 . The precast floors  40  are connected to the pilaster  300  using 1⅛″ ID sleeves that penetrate through the thickened precast floor edge of the floor panel, and have a 1″ diameter steel rod and adhesive. 
       FIG. 19  is a plan view of the two columns  62  that are mounted on the floor panels  40  of two adjacent modules. The edges of the bases of the columns are flush with or close to the edges of the floors  40 . The sleeves  290 , each complete with a steel rod and adhesive, and which pass through the thickened portion of the precast floor panel  40  and into the pilaster  300 , are shown. The line  330  of the pier (i.e. pilaster  300 ) is also shown. 
       FIG. 21  is a view of the columns  61  at the module interiors. The two columns are mounted on the floor panels  40  of two adjacent modules. The edges of the base plates of the columns are flush with or close to the edges of the floors  40 . A sleeve  290 , complete with a steel rod and adhesive, passes through the precast floor panel  40  and into the pier  330 . 
       FIG. 25  shows a porte cochere column cap connection. The precast column cap  370  is connected to the tops of precast wall panels  9  via rolled rod  20  to fit the gap, complete with foam backer rod and sealant. 
       FIG. 29  shows the connection at a pilaster. Floor and exterior wall of module are shown above a pile  510  complete with pile cap. All exterior concrete slopes away from the module on a minimum 2% grade  470  and contain 10M dowels  460  at 48″ (1.2 m) spacing drilled 6″ into the module foundation wall  500  (pier) with adhesive. At the foundation the pile  510  is capped before transitioning into a superior pier  500 . At the remote end of the concrete slab its edge  490  typically thickens as it does within the floors of the building project, with the horizontal rebar bent down  480  following the thickening edge to reinforce it. 
       FIG. 30  shows an interior pile  510  where the floors  40  of two modules meet. Both modules share the supporting pile and their columns  61  are vertically in line with it. Between each module&#39;s concrete slab and the pile is an elastomeric bearing pad  60  a pile cap  511  underneath. The thickened portions of the floors of two adjacent modules are supported on the elastomeric bearing pad  60 . The remainder of the volume underneath the slabs and surrounding the pile contains fill. 
     M. Roof Connections 
     Roof connections are shown in  FIGS. 3, 5, 22, 23, and 46 , for example. The ceiling of a unit is mounted below a roof on the module so that each self-contained unit is weather-proofed during transportation and construction and sealed vertically from neighbouring unit water-damage when occupied. The roof is welded to the top perimeter of the frame. 
       FIG. 3  shows roofs  45  supported from brackets  46  at the top part of the columns  61 .  FIG. 5  shows a roof  45 , which is corrugated, supported from the top part of the wall panel  17  of the lower module  250 . 
       FIG. 22  shows a parapet extension splice. Two exterior walls  7 ,  8  are shown one above the other. Embeds  30  are present in the outer layers of the walls  7 ,  8 . Between the bottom of the upper wall  7  and the top of the lower wall  8 , a rolled rod  20  to fit the gap is present, complete with foam backer rod and sealant. 
       FIG. 23  shows a roof deck parallel to span. The roof deck  45  is part of a module. The roof deck is connected to a precast wall panel  6 . PSA embeds  340  are present in the wall  6 . 
       FIG. 46  displays the roof connection at its high parapet. The roof is connected to module  250 . Connections  620  between the precast panels are at a 48″ (1.2 m) spacing. The precast modular wall extends beyond the roof floor with an additional modular wall attached atop it to create a visitor safety barrier. The precast panel to panel connection forming that extended wall is at 48″ (1.2 m) spacing and has opposing embedded metal rods on either side of the gap in both the inner and outer concrete slab pieces of the precast wall sandwich which make the connection. The module beam forming the building roof connects to its modular wall with paired metal rods from a steel plate angle attached to the beam and embedding into the module wall. 
     N. Variations 
     In general, unless otherwise indicated, singular elements may be in the plural and vice versa with no loss of generality. Examples of other embeds that may be used in the modules are shown in  FIGS. 49, 51, 52, 54 and 56 . 
     Throughout the description, specific details have been set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail and repetitions of steps and features have been omitted to avoid unnecessarily obscuring the invention. Accordingly, the specification is to be regarded in an illustrative, rather than a restrictive, sense. 
     It will be clear to one having skill in the art that further variations to the specific details disclosed herein can be made, resulting in other embodiments that are within the scope of the invention disclosed. All parameters, dimensions, materials, and configurations described herein are examples only and actual values or ones of such depend on the specific embodiment. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the appended claims. 
     O. Numbered Embodiments 
     1. A building module comprising: 
     a precast concrete floor with opposing edges thickened below the floor; 
     a frame comprising hollow structural section bars attached to a top surface of the precast concrete floor over the thickened edges; and 
     a roof attached to the frame. 
     2. The building module of embodiment 1, wherein the frame comprises columns that are bolted to the precast concrete floor and multiple horizontal members that define a top perimeter of the frame.
 
3. The building module of embodiment 1, comprising studding extending between the precast concrete floor and a horizontal member of the frame that defines a top edge of the frame.
 
4. The building module of embodiment 1, wherein the roof is welded to the frame.
 
5. The building module of embodiment 1, comprising a building exterior wall panel attached to the frame.
 
6. The building module of embodiment 5, wherein the exterior wall panel is located on and overhanging an end of the precast concrete floor, the end of the precast concrete floor being perpendicular to the thickened edges.
 
7. The building module of embodiment 5, wherein the exterior wall panel has a lower portion of an interior side thereof abutting an outer side of the thickened edge.
 
8. The building module of embodiment 5, wherein the exterior wall panel has an outer precast concrete layer, a middle insulating layer and an inner precast concrete layer.
 
9. The building module of embodiment 8, wherein a top surface of the inner precast concrete layer is lower than a top surface of the outer precast concrete layer.
 
10. The building module of embodiment 1, mounted on a plurality of elastomeric bearing pads underneath the thickened edges.
 
11. The building module of embodiment 1 in combination with another building module located below the building module, wherein a pin and void locating feature aligns the building module with the other building module.
 
12. The building module of embodiment 1, wherein the thickened edges terminate at a distance from an end of the precast concrete floor.
 
13. The building module of embodiment 1 in combination with another building module, wherein:
 
     a portion of the precast concrete floor extends beyond similar ends of the thickened edges to a connection with a portion of a precast concrete floor of the other building module; and 
     the portion of the precast concrete floor of the other building module extends beyond similar ends of the thickened edges of the precast concrete floor of the other building module to the connection. 
     14. The building module of embodiment 1, wherein hollow structural section bars are steel.
 
15. A building comprising a building module that comprises:
 
     a precast concrete floor with opposing edges thickened below the floor; 
     a frame comprising hollow structural section bars attached to a top surface of the precast concrete floor over the thickened edges; and 
     a roof attached to the frame. 
     16. The building of embodiment 15 comprising another building module and a corridor, wherein: 
     a portion of the precast concrete floor extends beyond similar ends of the thickened edges to a connection with a portion of a precast concrete floor of the other building module; 
     the portion of the precast concrete floor of the other building module extends beyond similar ends of the thickened edges of the precast concrete floor of the other building module to the connection: 
     a floor of the corridor is formed by: 
     the portion of the precast concrete floor that extends beyond the end of the thickened edges of the building module; and 
     the portion of the precast concrete floor of the other building module that extends beyond the thickened edges of the precast concrete floor of the other building module. 
     17. The building of embodiment 16, wherein the connection comprises a steel plate that is connected to embedded plates that are cast into said extended portions of said precast concrete floors.
 
18. The building of embodiment 15, wherein the thickened edges terminate at a distance from an end of the precast concrete floor.
 
19. The building of embodiment 18 comprising a balcony formed by a portion of the precast concrete floor that does not have thickened edges.