Method for producing a modular building unit

Abstract

A process for fabricating a building module is disclosed and claimed. The building module includes a load bearing frame, preferably utilizing metal components welded together. The frame is produced in subsections, namely two portal frame subsections, a floor frame subsection, a roof frame subsection, and optionally cantilever section frame subsections. The various frame subsections are assembled with the use of jigs which monitor correctness of the appropriate components, after which the subsections are transferred to a final frame assembly site, where they are located on jigs which properly position same with respect to other subsections, after which the subsections are secured to each other to form a unified module frame. The frame is then lifted and casters or the like are removably secured to a lower portion of same, whereby the completed frame may be moved, preferably on a trackway, past a plurality of finishing stations where predetermined further assembly steps are performed at each such station. In a most preferred embodiment, a monolithic concrete slab floor is utilized in conjunction with the module frame with pouring formwork removably secured to the frame at the final assembly site for movement with the frame to a pouring station where the concrete is cast into the formwork, finished and cured. Thereafter the formwork is removed and the frame is moved past the remaining module finishing stations. A building module may thus be virtually completed in a factory environment, except for fabrication steps that are required to be conducted at the building site relative to association of one module to another to ensure coplanarity of adjacent surfaces and to properly locate the module on an appropriate foundation.