MODULE-TO-MODULE CONNECTION IN MODULAR CONSTRUCTION

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/640,722, filed Apr. 30, 2024, the entirety of which is hereby incorporated by reference.

FIELD

The present disclosure generally relates to modular construction and, more particularly, to connections between modules in modular construction.

BACKGROUND

Construction modules or modular building units are used to construct a building by arranging (e.g., stacking, placing side-by-side, placing end-to-end, etc.) the modules relative to one another. When arranged to form the building, the modules form the framework (e.g., structural framework) of the building.

SUMMARY

In one aspect, a modular building unit for use forming a portion of a building having other modular building units generally comprises a plurality of beams and a column assembly attached to one or more beams of the plurality of beams. The column assembly includes an elongate interior, a first cable mount, and a second cable mount. The elongate interior is sized and shaped to permit one or more tension cables to extend therein. The first cable mount is disposed in the elongate interior and is arranged to mount a first tension cable coupled to an underlying modular building unit of said other modular building units in the elongate interior. The second cable mount is disposed in the elongate interior and is arranged to mount a second tension cable coupled to an overlying modular building unit of said other modular building units in the elongate interior.

In another aspect, a building framework of a building generally comprises a first modular building unit having a first structural frame. The first structural frame includes a first column assembly having a first elongate interior and a first cable mount disposed in the first elongate interior. The building comprises a second modular building unit overlying the first modular building unit. The second modular building unit has a second structural frame supported by the first structural frame. The second structural frame includes a second column assembly having a second elongate interior aligned with the first elongate interior and a second cable mount disposed in the second elongate interior. The building comprises a tension cable disposed in the first and second interiors and coupled to the first and second cable mounts.

In another aspect, a method of erecting a building framework of a building generally comprises coupling a free end of a tension cable to a first structural frame of a first modular building unit. The tension cable extends from a second structural frame of a second modular building unit. The method comprises positioning the second modular building unit over the first modular building unit such that the second structural frame rests on the first structural frame. The positioning occurs after said coupling the tension cable to the first structural frame of the first modular building unit. The method further includes coupling the tension cable to the second structural frame of the second modular building unit.

In another aspect, a column assembly for use in a modular building unit generally comprises a shaft and a node connected to an end of the shaft. The node is constructed to mount an end of a tensioning cable therein. The node includes a tubular portion and a flange projecting from the tubular portion. The flange is sized and shaped for connection to one or more beams of the modular building unit.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, plan view of two stories of a building framework made up of modular building units;

FIG. 2 is a perspective of a modular building unit according to one embodiment of the present disclosure;

FIG. 3 is an image of the modular building unit;

FIG. 4 is an elevation of the modular building unit;

FIG. 5 is an image of a column assembly of the modular building unit;

FIG. 6 is an enlarged, fragmentary perspective of an interface of two column assemblies with parts of the column shafts shown transparent to reveal internal construction;

FIG. 7 is an enlarged, fragmentary elevation of the interface of two column assemblies;

FIG. 8 is an image of an upper node of the column assembly;

FIG. 9 is a perspective of a cable mount of the column assembly;

FIG. 10 is a top view of the upper node of the column assembly;

FIG. 11 is a flow diagram for erecting the building framework with the modular building units; and

FIG. 12 is an image of a post-tension stressing jack tensioning a cable in the column assembly of the modular building unit; and

FIG. 13 is an exemplary image of a post-tension stressing jack tensioning a cable.

Corresponding reference characters indicated corresponding parts throughout the drawings.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to FIG. 1, a partially assembled building framework (e.g., a skeleton, a frame, a steel cage, or a cage) of a building constructed according to the teachings of the present disclosure is indicated generally at reference numeral 10. The building framework 10 is made up of a plurality of modular building units or modules 12 arranged next to one another. Each modular building unit forms a portion of the building (e.g., a portion of the building framework 10). As used herein, the building framework may refer to a substantially completed building with at least some interior finishes, to a skeleton of structural (e.g., weight bearing) members, and anything between. FIG. 1 illustrates the forming of another story of the building by placing a new modular building unit on top of an existing modular building unit and next to other modular building units of the same story. As illustrated, each story of the building framework 10 includes eight modular building units 12 placed side-by-side with one another in a 2×4 grid arrangement. The eight modular building units 12 are stacked on a lower story also comprising eight modular building units. In other embodiments, the building framework may include more or fewer modular building units and/or other arrangements of the modular building units. As used herein, modular building unit may refer to a substantially completed modular building unit with at least some interior finishes, to a skeleton of structural (e.g., weight bearing) members, and anything between. Each modular building unit 12 includes a structural (e.g., weight bearing) frame or cage 14 (FIG. 2). The structural frame 14 forms a portion of the building framework 10. When the modular building units 12 are stacked on top of one another, the structural frames 14 thereof rest on the structural frames of respective underlying modular building units. The structural frames 14 of the modular building units 12 may be identical, generally identical, or different. One structural frame 14 will now be described in more detail with the understanding that the structure and concepts described apply to the structural frames of each building module 12, regardless of whether the other structural frames have an identical, generally identical, or different constructions.

Referring to FIGS. 2-4, the structural frame 14 comprises a plurality of interconnected structural (e.g., weight bearing) members, such as beams, posts, columns, joists, etc. The illustrated structural frame 14 is a rectangular parallelepiped (e.g., hexahedron) shape, but other shapes can be used without departing from the scope of the present disclosure. The structural frame 14 includes a plurality of column assemblies 16 (broadly columns), a plurality of beams 18, a plurality of posts 20, and a plurality of joists 22. The beams 18 are coupled to and interconnect the column assemblies 16, the posts 20 are coupled to, interconnect and vertically span between beams, and the joists 22 are coupled to, interconnect and horizontally span between beams. The posts 20 may also be broadly considered “columns,” although they differ in construction from the column assemblies 16. The structural frame 14 may also include a mounting frame 24 on one or more sides thereof for the mounting of a façade (not shown) of the building. The structural members of the structural frame 14 may comprise structural steel (broadly, metal) members, such as tube (e.g., hollow structural steel “HSS”) members, I-shaped members (e.g., I-beams), angled (e.g. L) members, channel members, and the like. In the illustrated embodiment, the beams 18 and joists 22 are I-beams and the posts 20 are HSS members, although other configurations can be used without departing from the scope of the present disclosure. The column assemblies 16 generally have an HHS configuration, as described in more detail below. In the illustrated embodiment, the structural members are coupled together using bolts (broadly, fasteners) although other methods of attachment, such as welding and/or rivets, can be used without departing form the scope of the present disclosure. The column assemblies 16 are all identical or nearly identical (with the main difference being the arrangement of connection plates 44 (FIG. 5) for connecting to the beams 18). Accordingly, one column assembly 16 will now be described in more detail with the understanding the description applies to the other column assemblies as well.

Referring to FIGS. 5-10, the column assembly 16 facilitates the coupling of modular building units 12 that are stacked on top of each other with tension cables 32 (broadly, tension members). The tension cables 32 connect the modular building units 12 together. The column assembly 16 has an elongate interior 34 sized and shaped to permit the tension cables 32 (broadly, one or more tension cables) to extend therein. Thus, the column assembly 16 generally houses the tension cables 32. The elongate interior 34 extends from the upper end (broadly, upper portion) of the column assembly 16 to the lower end (broadly, lower portion) of the column assembly. The elongate interior 34 has open upper and lower ends to permit the tension cables 32 to extending into and/or out of the elongate interior. This allows tension cables 32 from other column assemblies of other modular building units 12 (e.g., the modular building unit(s) above and/or below) to extend into the elongate interior 34 of the column assembly 16 and allows tension cables from the column assembly to extend into the elongate interiors of the other column assemblies for coupling the column assemblies together. Thus, the column assembly 16 (specifically, the elongate interior 34) of one modular building unit 12 is vertically aligned with one or more column assemblies (specifically, the elongate interiors thereof) of other modular building units disposed vertically above and/or below when the modular building units are arranged in the building framework 10.

In the illustrated embodiment, the column assembly 16 includes a capital or upper node 26, an upright member or shaft 28, and a base or lower node 30, although other configurations of the column assembly can be used without departing form the scope of the present disclosure. The shaft 28 is coupled to the upper node 26 and to the lower node 30. The shaft 28 extends downward from the upper node 26 and extends upward from the lower node 30. The upper node 26 forms an upper portion (e.g., upper end) of the column assembly 16 and the lower node 30 forms a lower portion (e.g., lower end) of the column assembly. The upper node 26, the shaft 28, and the lower node 30 each bound a portion of the elongate interior 34 of the column assembly 16. The upper and lower nodes 26, 30 each include a main body 36 and upper and lower mounting flanges 38 attached to the main body. The main body 36 is generally hollow, which forms part of the elongate interior 34. In the illustrated embodiment, the main body 36 has a generally HHS shape, although other shapes can be used without departing from the scope of the present disclosure. The upper mounting flange 38 is attached to the upper end of the main body 36 and the lower mounting flange is attached to the lower end of the main body.

The shaft 28 includes a tube 40 of generally rectangular cross section, and upper and lower mounting flanges 42 attached as by welding to the tube. The tube 40 is generally hollow, which forms part of the elongate interior 34. In the illustrated embodiment, the tube 40 has a generally HHS shape, although other shapes can be used without departing from the scope of the present disclosure. The upper mounting flange 42 is attached to the upper end of the tube 40 and the lower mounting flange is attached to the lower end of the tube. The upper mounting flange 42 of the shaft 28 is coupled to the lower mounting flange 38 of the upper node 26. The lower mounting flange 42 of the shaft 26 is coupled to the upper mounting flange 38 of the lower node 30. In the illustrated embodiment, fasteners (e.g., bolts) couple the mounting flanges 38, 40 together, although other suitable attachment methods, such as welding, can be used without departing from the scope of the present disclosure. As shown in FIGS. 6 and 7, the upper mounting flange 38 of the upper node 26 of one column assembly 16b and the lower mounting flange 38 of the lower node 30 of another column assembly 16a are configured to engage and/or be coupled to one another. In the illustrated embodiment, fasteners (e.g., bolts) couple the mounting flanges 38 together, although other suitable attachment methods, such as welding, can be used without departing from the scope of the present disclosure.

Within the structural frame 14, the column assembly 16 is attached to one or more beams 18 (broadly, other structural members) of the structural frame. In the illustrated embodiment, the column assembly 16 includes one or more connection or shear plates (broadly, connection flanges) 44 for coupling to the one or more beams 18. The connections plates 44 are attached (e.g., welded) to the upper and lower nodes 26, 30. The number, arrangement and orientation of each connection plate 44 depends on position of the column assembly 16 in the structural frame 14—e.g., depends on the number and arrangement of beams 18 coupled to the column assembly. Accordingly, the particular number, arrangement and orientation of the connection plates 44 for each column assembly 16 in the structural frame can vary as needed. The connection plates 44 provide attachment points for the beams 18. In the illustrated embodiment, fasteners (e.g., bolts) couple the connection plates 44 and beams 18 together, although other suitable attachment methods, such as welding, can be used without departing from the scope of the present disclosure.

The column assembly 16 includes one or more cable mounts 46 for coupling the one or more tension cables 32 to the column assembly. Each cable mount 46 is disposed in the elongate interior 34 of the column assembly 16. In the illustrated embodiment, each cable mount 46 is disposed adjacent the upper end of the elongate interior 34. In other words, the cable mounts 46 are attached to the upper portion of the column assembly 16. This positioning makes accessing the cable mounts 46 easier during installation (through the open upper end of the elongate interior 34), as will become apparent. In the illustrated embodiment, the cable mounts 46 are attached to the upper node 26, inside the main body 36. Each cable mount 46 mounts a tension cable 32 to the column assembly 16 in the elongate interior 34. Each cable mount 46 includes a mounting block 48 (FIG. 9). The mounting block 48 has an opening or channel 50 sized and shaped to receive the tension cable 32. The channel 50 permits the tension cable 32 to extend lengthwise through the cable mount 46. The channel 50 has an open side to permit the tension cable 32 to be moved laterally (e.g., in a direction generally perpendicular to the length of the tension cable) into the opening.

The mounting block 48 also includes a seating surface 52 arranged to engage a tension connector 54 secured to the tension cable 32. In the illustrated embodiment, the tension connector 54 comprises a barrel 55 (FIG. 13) and a wedge, whose construction and operation is understood by those skilled in the art and will be not be repeated here. However, other types of tension connectors can be used without departing from the scope of the present disclosure. The seating surface 52 can be an upper or lower surface of the mounting block 48 depending on the configuration of the cable mount 46 (see description below). In the illustrated embodiment, the mounting block 48 comprises two metal (e.g., steel) bars 56. The metal bars 56 are secured to the inner surface of the main body 36 of the upper node 26. In the illustrated embodiment, the metal bars 56 are welded to the inner surface, with the cross-hatching in FIG. 9 illustrating the weld surfaces of the metal bars 56 (see weld locations in FIG. 10). Other ways of attaching the metal bars 56 (broadly, the cable mount 46) can be used without departing from the scope of the present disclosure. Each cable mount 46 may include a retainer 58. The retainer 58 is configured to retain the tension cable 32 in the channel 50 of the mounting block 46. Specifically, the retainer 58 is arranged to block the open side of the channel 50 to inhibit the tension cable 32 from inadvertently moving out of the channel 50 through the open side (e.g., laterally out of the opening). The illustrated retainer 58 comprises a gate or crossbar, although other suitable retainers can be used without departing from the scope of the present disclosure. The gate is moveable (e.g., pivotable) between an open position and a closed position. In the open position, the gate permits the tension cable 32 to be inserted into the channel 50 (e.g., through the open side thereof) of the mounting block 46. In other words, the gate is arranged such that it does not block the open side of the channel 50. In the closed position, the gate retains the tension cable 32 in the channel 50 of the mounting block 46. In other words, the gate blocks the open side of the channel 50. In the illustrated embodiment, only one of the cable mounts includes a retainer 58. Other configurations of the cable mounts can be used without departing from the scope of the present disclosure.

In the illustrated embodiment, the column assembly 16 includes two cable mounts 46, a first or upper cable mount 46a and a second or lower cable mount 46b. The upper cable mount 46a mounts a first or upper tension cable 32a to the column assembly 16. The upper tension cable 32a is coupled to an overlying modular building unit 12 (e.g., a column assembly 16 thereof). Thus, the upper tension cable 32a couples the column assembly 16 (broadly, structural frame 14, even more broadly, modular building unit 12) of one modular building unit to an overlying column assembly of a modular building unit 12 stacked on top of said one modular building unit. For the upper cable mount 46a, the seating surface 52 is a lower surface. The barrel of the tension connector 54 for the upper tension cable 32a engages the lower seating surface 52. The lower cable mount 46b mounts a second or lower tension cable 32b to the column assembly 16. The lower tension cable 32b is coupled to an underlying modular building unit 12 (e.g., a column assembly 16 thereof). Thus, the lower tension cable 32b couples the column assembly 16 (broadly, structural frame 14, even more broadly, modular building unit 12) of one modular building unit to an underlying column assembly of a modular building unit 12 that said one modular building unit is stacked on top of. In some embodiments, the lower tension cable 32b is coupled to a foundation (not shown) to secure the column assembly 16 to the foundation, such as if the modular building unit 12 is the lower-most unit in the stack and rests on the foundation. For the lower cable mount 46b, the seating surface 52 is an upper surface. The barrel of the tension connector 54 for the lower tension cable 32b engages the upper seating surface 52. Other configurations can be used without departing from the scope of the present disclosure, such as more or fewer cable mounts and/or cable mounts being mounted at other positions along the elongate interior.

FIGS. 6 and 7 illustrate the coupling of two column assemblies 16a, 16b of two modular building units 12 stacked on top of each other. In FIG. 7, the horizontal broken line delineates the two column assemblies, with the upper column assembly 16a disposed above the horizontal broken line and the lower column assembly 16b disposed below the horizontal broken line. As shown, the upper column assembly 16a is resting on the lower column assembly 16b. One or more fasteners (e.g., bolts) may be used to couple the upper and lower column assemblies 16a, 16b together, via the mounting flanges 38 as described above. The cable mounts 46 of the lower column assembly 16a are illustrated. The upper cable mount 46a is coupled to the upper tension cable 32a. A tension connector 54 is attached to the lower end portion of the upper tension cable 32a engages the lower seating surface 52 of the upper cable mount 46a. The upper cable mount 46a includes the retainer 58 to hold the lower end portion of the upper tension cable 32a in the channel 50 of the upper cable mount. The upper tension cable 32a extends up through the open upper end of the elongate interior 34 of the lower column assembly 16b and into the elongate interior of the upper column assembly 16a. The upper end (not shown) of the upper tension cable 32a is coupled to a lower cable mount (not shown) of the upper column assembly 16a. Thus, the upper tension cable 32a couples the two column assemblies 16a, 16b together (broadly, the two modular building units 12). Similarly, the lower cable mount 46b is coupled to the lower tension cable 32b. A tension connector 54 is attached to the upper end portion of the lower tension cable 32b engages the upper seating surface 52 of the lower cable mount 46b (note: this coupling of the upper end portion of the lower tension cable 32b to lower cable mount 46b can be the same as how the upper end portion of the upper tension cable 32a is coupled to the lower cable mount of the upper column assembly 16a). The lower tension cable 32b extends downward in the elongate interior 34 of the lower column assembly 16b, out through the open lower end of the elongate interior, and into the elongate interior of an underlying column assembly (not shown). The lower end (not shown) of the lower tension cable 32b is coupled to an upper cable mount (not shown) of this underlying column assembly (note: the coupling of the lower end portion of the lower tension cable 32b can be the same as how the lower end portion of the upper tension cable 32a is coupled to the upper cable mount 46a). Thus, the lower tension cable 32b couples another two column assemblies (column assembly 16b and another column assembly not shown) together (broadly, another two modular building units 12). This coupling of column assemblies 16 is repeated for each set of modular building units 12, one stacked on top of the other, along the height of the building, thereby connecting the modular building units in a vertical stack together to operate as a single vertical structural unit. In general, the tension cables 32 resist uplift forces experienced by the stack of modular building units, such as due to wind loads, to prevent the modular building units from lifting off one another.

The tension cables 32 are disposed in the elongate interiors 34 of the column assemblies 16 (see FIGS. 6 and 7). The two column assemblies 16a, 16b cooperate to house the entire portion of the upper tension cable 32a between the cable mounts 46 the upper tension cable is coupled to. This is the same for each tension cable 32 used to couple to structural frames 14 together. As a result, the tension cables 32 of the building framework 10 are hidden, protected, and out of the way. This allows other structural systems or other building systems to be used with the modular building units 12 without having to be modified or moved to accommodate the tension cables 32, unlike conventional tension systems which are generally exposed (e.g., disposed between columns) and need to be worked around. For example, as shown in FIG. 4, by positioning the tension cables 32 inside the column assemblies 16, a conventional lateral bracing system (e.g., strap bracing) 23 can be added to the structural frame 14 without having to accommodate the tension system (e.g., tension cables 32).

Still referring to FIGS. 6 and 7, in the illustrated embodiment, the column assembly 16 includes a stop 60 in the elongate interior 34 and underlying at least one of the cable mounts 46 (e.g., underlying at least the upper cable mount 46a). In the illustrated embodiment, the stop 60 is in the form of a floor that is part of the lower mounting flange 38 of the upper node 26. The stop 60 is arranged to limit the movement of the tension connector 54 attached to the tension cable 32 (e.g., the upper tension table 32a) before tension is applied to the tension cable to keep the tension connector aligned with the cable mount 54. The stop 60 may also serve as a support and brace for one of the cable mounts 46 (e.g., the lower cable mount 46b). The stop 60 may include openings therein to permit the tension cables 32 (e.g., tension cables 32a, 32b) to extend there-through. In other embodiments, the stop 60 may be omitted.

Referring back to FIGS. 2-4, preferably the upper end of the column assembly 16 is flush with a top surface of the structural frame 14 and the lower end of the column assembly is flush with a bottom surface of the structural frame. The top and bottom surfaces of the structural frame 14 are defined by the beams 18. Preferably, the structural frame 14 (broadly, the modular building unit 12) does not include any element disposed above the top surface (e.g., disposed above a plane in which the top surface lies in). Likewise, preferably, the structural frame 14 (broadly, the modular building unit 12) does not include any element disposed below the bottom surface (e.g., disposed below a plane in which the bottom surface lies in). This makes positioning the modular building unit 12 on another modular building unit easier, as the modular building unit is free to move in the horizontal plane relative to the underlying modular building unit. This freedom of movement makes it easier to stack the modular building units 12 on one another. This also allows any modular gasketing systems (not shown) of the modular building unit 12 to properly engage the other modular building units. For example, some modular gasketing systems require the modular building unit 12 to move horizontally into position in order to properly engage and seal between modular building units. Conventional modular connections typically include elements that protrude upward and/or downward, thereby limiting the ability of the modular building unit 12 to move horizontally, such as at the critical time when the modular building unit 12 is placed on the underlying modular building unit and the gasketing systems engage.

The column assembly 16 may include a lift attachment 62 (FIG. 4) for coupling the structural frame 14 to a crane (not shown). The lift attachment 62 may comprise a hook, an opening sized and shaped to receive a hook of the crane, or any other suitable lift attachment structure. The lift attachment 62 may be mounted to (e.g., part of) the upper node 26. Integrating the lift attachment 62 with the column assembly 16 makes it easier to connect and disconnect the modular building unit 12 with the crane. Further, because the column assembly 16 is a structural element (e.g., is made of structural steel), the modular building unit 12 can be lifted at the column assembly without significant deflections to the rest of the structural frame 14. This enables the modular building unit 12 to have all or some interior finishes and appliances installed prior to the modular building unit being arranged in the building framework 10. Conventional modular building units, especially those made out of wood, may experience significant deflections during lifting which can damage (e.g., crack, split, etc.) interior finishes. As a result, conventional modular building units must be sufficiently reinforced before lifting, adding to material and labors costs, or wait until the modular building unit is positioned in the building framework to apply the interior finishes.

In the illustrated embodiment, the structural frame 14 includes six column assemblies 16, although more or fewer column assemblies in a structural frame can be used without departing from the scope of the present disclosure. One column assembly 16 is positioned at each corner of the structural frame 14, with another column assembly 16 positioned at an intermediate location along the elongate sides of the structural frame. Other positions of the column assemblies 16 within the structural frame 14 can be used without departing from the scope of the present disclosure. In some embodiments, the structural frame may include column assemblies 16 of the present disclosure and other column configurations. The other column configurations may include regular columns such as columns made of a single piece of structural steel or any other suitable column configurations, such as the posts 20 that can be seen in FIG. 2. In other words, the structural frame can include a mix of different types of column configurations, such as one or more column assemblies 16 of the present disclosure and one or more column configurations not like the column assemblies of the present disclosure.

Referring to FIG. 11, one method of erecting the building framework 10 with modular building units 12 of the present disclosure will now be described. The method will be described in relation to the installation of an upper modular building unit 12a on a lower modular building unit 12b of the building framework 10 (see FIG. 1). The method is described in relation to one column assembly 16 of the modular building unit 12 but it is understood that this method would generally be repeated for each column assembly in the modular building unit. At step 102, the tension cable 32 is threaded through the column assembly 16a of the upper modular building unit 12a. This may be done before, during, or after the structural frame 14 is assembled. After, at step 104, a tension connector 54 is attached to the lower end portion (e.g., dead end) of the tension cable 32. Steps 102 and 104 can occur while the upper modular building unit 12a is being assembled in a factory or in the field after the upper modular building unit is delivered to the construction site of the building. If needed, the upper end of the tension cable 32 can be temporality secured to the top of the column assembly 16, such as with tape, to prevent the tension cable from falling through the column assembly during installation.

After step 104, the upper modular building unit 12a is lifted and generally moved near its final position in the building framework 10, over the lower modular building unit 12b. Before the upper modular building unit 12a is lowered onto the lower modular building unit 12b, the lower end of the tension cable 32 is inserted into the elongate interior 34 of the column assembly 16b of the lower modular building unit 12b, at step 106. An operator grabs the tension connector 54 connected to the lower end of the tension cable 32, aligns the tension cable 32 with the channel 50. The gate 58 is in an opened position. The operator moves the tension connector 54 and tension cable 32 so that the tension cable moves past the gate into the channel 50. The tension connector 54 is moved into position underlying the lower seating surface 52 of the upper cable mount 46a (broadly, open upper end of the elongate interior 34) of the column assembly 16b of the lower modular building unit 12a. The operator closes the gate 58 to keep the tension cable 32 in the channel 50. The tension connector 54 now lies below the upper cable mount 46a of the column assembly 16b of the lower modular building unit 12b, ready to engage the lower seating surface 52 of the upper cable mount. The retainer 58 keeps the tension cable 32 in the channel 50 while the tension cable is still loose (e.g., before tension is applied to forcibly seat the tension connector 54 against the upper cable mount 46a) and the upper modular building unit 12a is moved to its final position in the building framework 10. At this point, the tension cable 32 still extends through the column assembly 16a of the upper modular building unit 12a, with an upper portion (e.g., live end) of the tension cable extending out of the top of the column assembly. With the lower end of the tension cable 32 coupled to the lower modular building unit 12b, at step 108, the upper modular building unit 12a is positioned over the lower modular building unit such that the structural frame 14a of the upper modular building unit rests on the structural frame 14b of the lower modular building unit. As the upper modular building unit 12a is lowered onto the lower modular building unit 12b, the tension cable 32 may be used to help align the upper modular building unit relative to the lower modular building unit. With the upper modular building unit 12a stacked on the lower modular building unit 12b, the operator may install the fasteners through the mounting flanges 38 to couple the two column assemblies 16a, 16b together. The upper modular building unit 12a is now in its final position in the building framework 10.

After the upper modular building unit 12a is positioned on the lower modular building unit 12b, the operator couples the tension cable 32 to the column assembly 16a of the upper modular building unit 12a. Another tension connector 54 is attached to the upper end portion of the tension cable 32, at step 110. The operator also inserts the tension cable 32 into the opening 52 of the lower cable mount 46b in the column assembly 16a of the upper modular building unit 12a. This also arranges the tension connector 54 connected to the upper end portion of the tension cable 32 above the lower cable mount 46b, ready to engage the upper seating surface 52 of the lower cable mount. After, at step 112, the operator tensions the tension cable 32. The operator attaches the upper end portion of the tension cable 32 to a post-tension stressing jack 33 (FIGS. 12 and 13). FIG. 12 shows the post-tension stressing jack 33 coupled to the tension cable 32 and arranged relative to the column assembly 16 to tension the tension cable. It is appreciated that the tension cable 32 has excess length (see FIGS. 2 and 12) to allow the tension cable to be attached to the post-tension stressing jack 33 (and for other reasons, such as lowering the tension cable to connect the tension cable to the lower modular building unit 12b). The operator then operates the post-tension stressing jack 33 to tension the tension cable 32. As the tension cable 32 is tensioned, one tension connector 54 engages the upper cable mount 46a of the column assembly 16b of the lower modular building unit 12b and the other tension connector engages the lower cable mount 46b of the column assembly 16a of the upper modular building unit 12a—thereby securing the tension cable to the two column assemblies. The post-tension stressing jack 33 includes a nose 35 (FIG. 13) through which the tension cable 32 enters the post-tension stressing jack and which engages and pushes the tension connector 54 attached to the upper end portion of the tension cable against lower cable mount 46b. The open upper end of the elongate interior 34 is sized and shaped to permit the nose 35 of the post-tension stressing jack 33 to be inserted into the elongate interior 34, to push the tension connector 54 against lower cable mount 46b. In one embodiment, the post-tension stressing jack 33 tensions the tension cable 32 to about 50 Kips, which due to seating loss will typically result in a final, at-rest tension of about 35 Kips in the tension cable. After the tension cable 32 is tensioned, the operator removes the post-tension stressing jack 33 and cuts off the excess length of the tension cable. This process is then repeated for the next modular building unit 12 of the building framework 10.

While not shown relative to a modular building unit 12 of the present disclosure, FIG. 13 shows the post-tension stressing jack 33 coupled to a cable (such as tension cable 32) with a tension connector 54 mounted thereon for tensioning the cable. The arrangement of the post-tension stressing jack 33, the cable 32, and the tension connector 54 shown in FIG. 13 is similar to how these components would be arranged relative to one another when used with the modular building unit, with one difference being the tension connector 54 would be seated against the cable mount 46 of the upper node 26 (not shown in FIG. 13).

The connection system of the present disclosure is a scalable and adaptable solution for modular building units 12 that allows for verification of the tension capacity in the tension cable 32 (via the post-tension stressing jack 33), enables transport and rigging into position (via the attachment points 62), and allows for a systemic deployment of the tension cables within the structural frame 14 of the modular building unit such that the modular building unit does not require a series of project specific solutions. Housing the tension cable 32 within the column assembly 16 ensures the tension cable can be housed and transported with dimensional fixity, as well as protecting the tension cable after the tensioning has occurred. The attachment points 62 provide a vertical structural means of lifting the modules such that any ceiling, walls and/or floor of the modular building unit 12 are all pulled upward consistently, with minimal deflections. The upper node 26 of the column assembly 16 housing the cable mounts 46 for the tension cable 32 and the upper and lower nodes 26, 30 providing the attachment points for the connection plates 44, allows the column assembly 16 to be easily adjusted (such as by varying the length (e.g., height) of the shaft 28) to different project scales and types while maintaining a consistent approach. The upper and lower nodes 26, 30 can also be used to for the attachment of adjacent material wall, floor or ceiling systems or façade assemblies (e.g., the mounting frame 24). The connection system of the present disclosure also allows for the horizontal and vertical movement of the modular building unit 12 into position to enable self-gasketing façade engagement (via the lack of protruding elements above and below the structural frame 14), provides for verifiable non-invasive connections to be provided during setting of modules (via the measuring of the tension applied by the post-tension stressing jack 33 during tensioning), and aids in the sweeping of modules into their correct position once the lower or dead end of the tension cables 32 are connected into underlying modular building unit (as mentioned above, the tension cables 32 aids guidance and alignment of the modular building unit with respect to the underlying modular building unit such that typically used additional external drag lines or come-alongs are not needed).

As used herein and in the drawings, when a reference character includes a reference numeral not followed by a letter, such a reference character refers to all elements designated at least in part by the reference numeral. Moreover, when a reference character includes the reference numeral followed by a letter, such as “a,” such a reference character refers to a particular element from the group of elements. For example, as used herein and in the drawings, reference numeral “16” designates all column assemblies, while reference numeral “16” followed by a letter, such as “16a”, designates a specific column assembly.

While some numeric identifiers such as “first” and “second” may have been described herein in relation to a specific component, element, or feature, it is understood that any corresponding use of these numeric identifiers in the claims is not limited to referring to only said specific component, element or feature mention above. Instead, these numeric identifiers are used in the claims to identify different components.

Modifications and variations of the disclosed embodiments are possible without departing from the scope of the disclosure defined in the appended claims.

When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

As various changes could be made in the above constructions, products, and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Other Statements of the Disclosure

The following are statements or features described in the present disclosure. Some or all of the following statements may not be currently presented as claims. Nevertheless, the statements are believed to be patentable and may subsequently be presented as claims. Associated apparatuses corresponding to the statements or methods below (and vice versa) are also believed to be patentable and may subsequently be presented as claims. It is understood that the following statements may refer to and be supported by one, more than one, or all the embodiments described above.

A1. A method of erecting a building framework of a building, the method comprising:

• • coupling a free end of a tension cable to a first structural frame of a first modular building unit, the tension cable extending from a second structural frame of a second modular building unit;
  • positioning the second modular building unit over the first modular building unit such that the second structural frame rests on the first structural frame, wherein said positioning occurs after said coupling the tension cable to the first structural frame of the first modular building unit; and
  • coupling the tension cable to the second structural frame of the second modular building unit.

A2. The method of statement A1, further comprising threading, before said coupling the tension cable to the first structural frame of the first modular building unit, the tension cable through a column assembly of the second structural frame.

A3. The method of statement A1, wherein said coupling the tension cable to the second structural frame of the second modular building unit includes tensioning the tension cable with a post-tension stressing jack.

A4. The method of statement A1, wherein said step of positioning the second modular building unit comprises locating the second modular building unit over the first modular building unit in proximity to permit said step of coupling the tension cable to the first structural frame of the first modular building unit, and then pulling the tension cable to move the second modular building unit more precisely into alignment with the first modular building unit.

A5. The method of statement A1, wherein connection of the second modular building unit to the first modular building unit is achieved without welding.